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Range Rover. Manual - part 267

PANEL REPAIRS

REPAIR

REAR FLOOR EXTENSION PANEL

Remove

1. Disconnect both battery leads, negative lead

first.

2. Raise rear of vehicle.

WARNING: Support on safety stands.

3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
5. Disconnect alternator.
6. Remove tailgate - lower.

See CHASSIS AND

BODY, Repair.

7. Remove rear bumper valance.

See CHASSIS

AND BODY, Repair.

Refit

8. Prepare and clean panel joint faces. Punch or

drill holes in new rear crossmember extension
panel for plug welding as shown.

9. Reverse removal procedure.

10. Remove stands and lower vehicle.

SPARE WHEEL CLOSING PANEL

Remove

1. Disconnect both battery leads, negative lead

first.

2. Disconnect all ECUs.
3. Disconnect airbags and sensor system.
4. Disconnect alternator.
5. Remove rear seat belt - left hand.

See

CHASSIS AND BODY, Repair.

6. Remove rear seat belt - right hand.

See

CHASSIS AND BODY, Repair.

7. Remove rear seatbelt - centre.

See CHASSIS

AND BODY, Repair.

Refit

8. Prepare and clean panel joint faces. Punch or

drill holes in new spare wheel closing panel for
plug welding as shown.

9. Reverse removal procedure.

PANEL REPAIRS

NEW RANGE ROVER

REPAIR

LOWER PANEL

Remove

1. Disconnect both battery leads, negative lead

first.

2. Disconnect all ECUs.
3. Disconnect airbags and sensor system.
4. Disconnect alternator.
5. Remove tailgate - lower.

See CHASSIS AND

BODY, Repair.

6. Remove tailgate striker.

See CHASSIS AND

BODY, Repair.

7. Remove rear bumper valance.

See CHASSIS

AND BODY, Repair.

Refit

8. Prepare and clean panel joint faces. Punch or

drill holes in new lower panel for plug welding as
shown.

WARNING: remove ALL traces of adhesive
from joints to quarter panels before plug
welding.

9. Reverse removal procedure.

PANEL REPAIRS

PAINT

PAINT PROCEDURES

Replacement Panels
Service panels are supplied with a cathodic primer
coating as part of the panel protection, and in
compliance with the vehicle’s Corrosion Warranty
where applicable. DO NOT remove this primer
before paint refinishing. In the event of localised
surface damage or imperfections, ensure that the
minimum of primer is removed during rectification
work for effective repair.

Rectify damage by panel beating or straightening. To
remove corrosion or paint runs on outer surfaces,
abrade primer coat in the affected area as necessary
using the following procedure:

1. Clean the panel using a solvent wipe.
2. Treat exposed areas of metal with an etch

phosphate process.

3. Re-treat the affected area using either a

separate acid-etch primer and two-pack
surfacer, or an integrated etch primer/filler.

Bolted Panels
Before fitting bolt-on panels, ensure that all mating
and adjacent surfaces on the vehicle and replacement
panel are free from damage and distortion. Rectify if
necessary as described in this section, and apply
preformed strip sealer where specified.

Welded Panels

1. Remove primer from the immediate vicinity of

new and existing panel flanges, cleaning to
bright metal finish.

2. On joints to be spot welded, apply weld-through

zinc rich primer to joint faces of both flanges.
Make spot welds while primer is still wet or
according to the manufacturer’s instructions.

3. Dress accessible weld seams.
4. Clean panel using solvent wipe.
5. Treat bare metal with an etch phosphate

process.

6. Re-treat repaired areas.

NOTE: It is not satisfactory to use
weld-through, zinc rich primers in
conjunction with arc or MIG welding.

Sectioned Panels
When replacing part or sectioned panels, the basic
procedure is the same as for welded panels described
above, with the following variations:

1. Remove primer from both new and existing joint

faces, cleaning to a bright metal finish.

2. Where an overlap joint with the existing panel is

to be spot welded, apply weld-through, zinc rich
primer to both joint faces and spot weld while the
primer is still wet or according to the
manufacturer’s instructions.

3. MIG weld butt joints where applicable.
4. Clean the panel with a solvent wipe.
5. Treat bare metal areas using an etch phosphate

process.

6. Re-prime affected areas as necessary as for

rectifying transit damage. See this section.

7. Treat the inner faces of lap or butt joints with a

suitable cavity wax. See Sealing and corrosion
protection.

PANEL REPAIRS

NEW RANGE ROVER

PAINT

Clinch Panels (eg Door skins etc.)

1. Abrade primer on new and existing panel joint

faces, and clean using a solvent wipe.

2. Apply metal-to-metal adhesive where applicable.
3. Where joints are to be spot welded, apply

suitable weld-through, zinc rich primer to weld
areas.

4. Where joints are to be MIG, arc or gas welded,

apply zinc rich primer in adjacent areas but
leave the welded area untreated.

5. To retain the panel whilst clinching the flanges,

tack spot weld or plug weld as appropriate.

6. Clean the panel with a solvent wipe.
7. Treat bare metal areas with a suitable etch

phosphate process.

8. Re-prime affected areas as necessary as for

rectifying transit damage. See this section.

NOTE: Replacement doors, bonnets and
tailgates must be treated with a suitable
seam sealer on clinched seams, following

the primer coat.

Paint Refinishing

1. Seal all accessible exterior and interior seams

with an approved seam sealer. Certain joints
such as sill lower flange seams must be left
unsealed.

2. Apply a suitable anti-chip primer where

specified.

3. Apply a two-pack paint refinishing system.
4. Repair any damage to underbody sealers either

at this stage or before paint operations.

Paint Repairs
Before carrying out paintwork repairs, the vehicle
must be thoroughly cleaned using either a steam
cleaner or high-pressure washer.

Wash locally repaired areas using a mild
water-mixable detergent and wipe them clean with
solvent, immediately prior to paint application.

Abrade damaged paintwork where bare metal has
been exposed until the metal is clean and extends
beyond the area of immediate damage. Treat the bare
metal with an etch phosphate to remove all traces of
rust and provide a key for new paint coats. Re-treat
the affected area using either a separate acid-etch
primer and two-pack surfacer or an integrated etch
primer/filler, and follow with a two-pack paint system.
Those surfaces not receiving paint must be treated
with a cavity wax following paint operations.

A. Two-pack top coat

B. Two-pack primer filler and etch primer

C. Etch phosphate

Content .. 265 266 267 268 ..