Range Rover. Manual - part 248

CHASSIS AND BODY

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 separately 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.

CHASSIS AND BODY

NEW RANGE ROVER

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 approximately 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.

CHASSIS AND BODY

REPAIR

25. Apply a continuous bead of sealer to backlight

as shown.

26. Original glass:Apply 3mm bead of sealer to

channels of side finishers and fit to backlight.

27. Fit suction lifters to glass.
28. With assistance, fit glass and centralize to

previously made tape markings. Set glass to
correct depth.

29. Connect screen heater.
30. Remove reference and protective tapes.
31. Position lower finisher and secure to clips.
32. Fit interior trim to tailgate,

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.

REAR QUARTER LIGHT

Service repair no - 76.81.20

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.

NOTE: New rear quarter glass is supplied
with exterior trim fitted.

WARNING: Wear protective gloves when
handling glass, solvents and primers.

Remove

1. Remove parcel tray support,

See this section.

2. Remove both ’E’ post trims,

See this section.

3. Remove relevant ’B’ post upper trim,

See this

section.

4. Remove relevant side interior lamp assembly,

See ELECTRICAL, Repair.

5. Remove relevant grab handle,

See this

section.

6. Remove relevant exterior ’E’ post finisher,

See

this section.

CHASSIS AND BODY

NEW RANGE ROVER

REPAIR

7. Remove 2 trim studs securing headlining to ’E’

posts.

8. Release headlining from tailgate seal. Lower

headlining as necessary during glass removal to
provide access to sealant along top edge of
glass.

9. Disconnect aerial amplifier plugs.

10. R.H. glass only:Disconnect alarm receiver plug.
11. Protect surrounding area of body using masking

tape.

Removal Using Reciprocating Blade Tool

12. Lift flip seal to reveal trim fixings.

13. Remove 2 screws securing exterior trim to ’D’

post.

14. Cut through P.U. adhesive from inside of glass

along lower and side edges.

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