Range Rover Body Repair Manual — part 37
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CHASSIS AND BODY
73
REPAIR
WINDSCREEN
Service repair no - 76.81.01
NOTE: The following equipment is
required:
masking tape;
sharp knife;
reciprocating blade, powered cutting knife*, or
cutting wire and handles;
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.
CAUTION: Extreme care is necessary to
ensure that paintwork and trim does not
become damaged during the removal
process.
Particular care should be taken when using
cutting wire and handles to avoid damage to seal
along leading edge of fascia.
WARNING: Wear protective gloves when
handling glass, solvents and primers.
Remove
1. Remove interior mirror.
See this section.
2. Remove plenum panels.
See HEATING AND
VENTILATION, Repair.
3. Insert a thin plastic strip, such as a credit card,
between windcreen upper finisher and roof
panel.
4. Disengage 8 clips securing upper finisher by
sliding clips towards left hand side of vehicle.
5. Remove upper screen finisher.
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76
CHASSIS AND BODY
NEW RANGE ROVER
74
REPAIR
6. If fitted, disconnect heating element multiplugs.
Disconnect heating element earth wire. Tape
heater connections onto windscreen to prevent
fouling during removal procedure.
7. Mask around windscreen aperture to protect
paintwork.
8. Fit protective cover over fascia and bonnet.
Removal Using Reciprocating Blade Tool
9. Cut through P.U. adhesive along sides of screen
using flat blade.
10. Using a ’U’ shaped blade, cut through adhesive
bead along upper and lower edges of screen.
CAUTION: Access to adhesive around
lower screen supports is restricted.
Manoeuvre blade to cut as much sealant
from around screen supports as possible.
11. Attach suction lifters to glass. With assistance,
cut through remaining sealant around screen
supports using a sharp knife.
12. With assistance, remove windscreen glass.
Removal Using Cutting Wire and Handles.
13. Remove both ’A’ post finishers.
See this
section.
14. Remove both sun visors.
See this section.
15. Remove map/courtesy lamp assembly.
See
ELECTRICAL, Repair.
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CHASSIS AND BODY
75
REPAIR
16. Mask along leading edge of headlining.
17. Using a sharp knife, cut through P.U. sealer at
side of screen, towards lower corner.
18. Insert cutting wire through knife cut and fit
handles, as shown, with approximately 200 mm
(8 in) of wire between handles.
19. 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
screen supports to reduce strain on wire.
20. Attach suction lifters to glass. With assistance,
remove windscreen.
Refit
21. carefully cut old sealer from body flange to
obtain a smooth surface, approximately 2 mm
(1/16 in) thick.
CAUTION: Do not cut down to painted
surface.
22. Inspect supports, renew if damaged.
23. Position screen on felt covered surface.
24. If original screen is to be refitted, cut old sealer
from glass to obtain a smooth surface,
approximately 2 mm (1/16 in) thick.
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76
CHASSIS AND BODY
NEW RANGE ROVER
76
REPAIR
CAUTION: Do not cut down to surface of
glass.
25. Position and centralise new windscreen to body.
Apply tape reference marks to aid final fitment.
Remove screen and position to work surface.
26. Apply cleaning solvent to sealing surface of
glass and body flange.
CAUTION: Do not touch cleaned or primed
areas with fingers.
27. Position 5 screen spacer blocks on inside edge
of glass, over cut-out marks in obscuration band.
28. If necessary, peel off backing strip and stick
foam glazing dam along inside surface of glass,
approximately 13 mm (1/2 in) from top edge.
29. Shake primer tins for at least 30 seconds. Apply
body primer to sealing surface of body flange
using supplied applicator.
30. Apply glass primer to sealing surface of glass.
CAUTION: Use a separate applicator for
each primer.
31. 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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