Range Rover Body Repair Manual — part 38
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CHASSIS AND BODY
77
REPAIR
32. Apply a continuous bead of sealer to windscreen
as shown.
33. Fit suction lifters to glass.
34. With assistance, position glass centrally, using
previously made tape markings and lower onto
supports. Seat glass to spacer blocks.
CAUTION: Do not apply heavy pressure to
the sides of the screen. Lightly press
screen from centre outwards until edges
are to required gap. Pushing screen edges into
position can bend screen and lead to cracking in
service.
35. Remove protection from fascia and bonnet.
36. Remove masking tape.
37. If fitted, connect heating element multiplugs and
earth wire.
38. Remove clips from upper screen finisher.
39. Fit clips to body studs. Position upper screen
finisher and engage to clips.
40. Fit plenum panels.
See HEATING AND
VENTILATION, Repair.
41. Fit interior mirror.
See this section.
If Cutting Wire and Handles Used
42. Remove masking from leading edge of
headlining.
43. Fit map/courtesy lamp assembly.
See
ELECTRICAL, Repair.
44. Fit sun visors.
See this section.
45. Fit ’A’ post finishers.
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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76
CHASSIS AND BODY
NEW RANGE ROVER
78
REPAIR
WINDSCREEN LOWER FINISHER
Service repair no - 76.43.41
Remove
1. Remove both windscreen side finishers.
See
this section.
2. Remove both windscreen wiper arms.
See
WIPERS AND WASHERS, Repair.
3. Release 10 clips securing windscreen lower
finisher.
4. Remove windscreen lower finisher.
Refit
5. Reverse removal procedure.
WINDSCREEN SIDE FINISHER
Service repair no - 76.43.39
Remove
1. Lift side finisher seal to reveal fixings.
2. Remove 4 screws securing side finisher.
3. Remove side finisher.
Refit
4. Position side finisher. Secure side with screws.
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CHASSIS AND BODY
79
REPAIR
BACKLIGHT GLASS
Service repair no - 76.81.10
NOTE: The following equipment is
required:
masking tape.
Sharp knife.
Cutting wire and handles, or a reciprocating
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 are required.
WARNING: Wear protective gloves when
handling glass, solvents and primers.
Remove
1. Remove interior trim from tailgate,
See this
section.
2. Release backlight lower finisher from 7 clips.
3. Remove backlight lower finisher.
4. Remove backlight side finishers.
NOTE: Side finishers are secured to
backlight with P.U. sealer. New backlight
glasses are supplied with side finishers
fitted. Side finishers are available separatley if
original glass is to be refitted.
5. Remove rubber finisher from upper edge of
backlight glass.
6. Protect tailgate panel with masking tape.
7. Disconnect two Lucar terminals from screen
heater element.
Removal Using Reciprocating Blade Tool
8. Cut through P.U. adhesive along sides of screen
using flat blade.
9. Using a ’U’ shaped blade, cut through adhesive
bead along upper and lower edges of glass.
CAUTION: Access around lower clips is
restricted. Manoeuvre blade to cut through
as much adhesive as possible.
10. Attach suction lifters to glass. With assistance,
cut through remaining sealant around lower
clips.
11. With assistance, remove backlight glass.
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76
CHASSIS AND BODY
NEW RANGE ROVER
80
REPAIR
Removal Using Cutting Wire Handles
12. Using a sharp knife, cut through P.U. sealer at
side of backlight.
13. Insert cutting wire through knife cut and fit
handles, as shown, with approximatley 200mm
of wire between handles.
14. With assistance, wedge tube of handle ’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
and restrain glass as last of sealant is cut.
NOTE: When cutting along lower edge,
manoeuvre wire between glass edge and
finisher clips to reduce strain on wire.
15. With assistance, remove backlight glass.
Refit
16. Carefully cut old sealer from body flange to
obtain a smooth surface, approximately 2mm
thick.
CAUTION: Do not cut down to painted
surface.
17. Renew broken finisher clips as necessary.
Position finisher clips centrally on tailgate studs.
NOTE: Clips control height and seating of
lower glass edge.
18. Position and centralize new backlight to tailgate.
Apply tape reference mark to aid final fitment.
19. Position new backlight on felt covered surface.
20. Fit and centralize rubber finisher to top of glass.
NOTE: Finisher controls seating depth of
glass top edge.
21. Apply cleaning solvent to sealing surface of
glass and body flange.
CAUTION: Do not touch cleaned or primed
areas with fingers.
22. Shake primer tins for at least 30 seconds. Apply
body primer to sealing surface of body flange
using supplied applicator.
23. Apply glass primer to sealing surface of glass.
CAUTION: Use a separate applicator for
each primer.
24. 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.
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