Range Rover Evoque: A-Pillar Outer Panel

Removal

NOTES:

The A-pillar outer panel is manufactured from mild steel. The fender mounting bracket is serviced on the new panel.

The upper and lower butt joint must be MIG brazed due to the location of a boron reinforcement.

A new anti tamper VIN indentification decal will be required when replacing the L/H A-Pillar panel.

1. The A-Pillar outer panel is replaced in conjunction with:

  1. Front bumper cover
  2. Hood
  3. Front fender
  4. Front door
  5. Instrument panel
  6. Windshield glass
  7. Headliner

Range Rover Evoque. Side Panel Sheet Metal Repairs - 5-Door

2. For additional information relating to this repair procedure please see the following: For additional information, refer to: Health and Safety Precautions (100-00 General Information, Description and Operation) / Body Repairs (501-25A Body Repairs - General Information, Description and Operation) / Corrosion Protection (501-25B Body Repairs - Corrosion Protection, Description and Operation) / Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation) / Standard Workshop Practices (100-00 General Information, Description and Operation).

3. Remove the front fender.

For additional information, refer to: Fender (501-02 Front End Body Panels, Removal and Installation).

4. NOTE: If any of the front fender retaining brackets are damaged they must be replaced.

Remove the bolt-on front fender retaining brackets from the a-pillar outer panel.

5. Remove the hood.

6. Remove the hood hinge.

7. Remove the front door.

For additional information, refer to: Front Door (501-03 Body Closures, Removal and Installation).

8. Remove the side air curtain module.

For additional information, refer to: Side Air Curtain Module (501-20B Supplemental Restraint System, Removal and Installation).

9. Remove the instrument panel.

For additional information, refer to: Instrument Panel - TD4 2.2L Diesel (501-12 Instrument Panel and Console, Removal and Installation) / Instrument Panel - GTDi 2.0L Petrol (501-12 Instrument Panel and Console, Removal and Installation).

10. Remove the windshield glass.

For additional information, refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).

11. NOTE: Right hand side for right hand drive, left hand side for left hand drive. Remove the wiper motor if required.

For additional information, refer to: Windshield Wiper Motor (501-16 Wipers and Washers, Removal and Installation).

12. Remove the upper and lower door hinges from the A-pillar, 4 x bolts. Torque 30Nm

13. Remove the cowl side trim panel.

For additional information, refer to: Cowl Side Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).

14. Remove the rocker panel inner trim.

For additional information, refer to: Front Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).

15. Remove the rocker panel outer moulding.

16. Remove the front seat.

For additional information, refer to: Front Seat (501-10 Seating, Removal and Installation).

17. Release and lay aside the front carpet.

18. Remove the roof moulding.

19. Release and lay aside the wiring harness along the A-Pillar inner and inner rocker panel.

20. Release and lay aside the insulating material at the inner bulkhead.

21. Remove the front wheel and tire.

For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).

22.

Range Rover Evoque. Side Panel Sheet Metal Repairs - 5-Door

23.

Range Rover Evoque. Side Panel Sheet Metal Repairs - 5-Door

24. Drill out the spot welds.

Range Rover Evoque. Side Panel Sheet Metal Repairs - 5-Door

25. NOTE: If the NVH components are damaged on separation, new components will be required. Separate the joints and remove the old panel, also releasing the NVH components from the old panel as indicated.

Range Rover Evoque. Side Panel Sheet Metal Repairs - 5-Door

Installation

1. Mark out the position where the A-pillar outer panel, upper MIG brazed butt joint is to be made.

Cut through the new panel as indicated.

Range Rover Evoque. Side Panel Sheet Metal Repairs - 5-Door

2. Mark out the position where the A-pillar outer panel, lower MIG brazed butt joint is to be made.

Cut through the new panel as indicated.

Range Rover Evoque. Side Panel Sheet Metal Repairs - 5-Door

3. Cut 8mm x 20mm slots as indicated in new panel.

Follow steps 1 to 3 as shown in the above inset.

Range Rover Evoque. Side Panel Sheet Metal Repairs - 5-Door

4. Drill holes in new panel ready for MIG plug welding as indicated.

Range Rover Evoque. Side Panel Sheet Metal Repairs - 5-Door

5. Prepare the old and new panel joint surfaces, including the NVH components.

6. NOTE: With panel in position check for access to spot weld the joints. Offer up the new panel and clamp into position. Check alignment, if correct, proceed to next step, if not, rectify and recheck before proceeding.

7. Remove the new panel.

8. NOTE: Care must be taken so that the threads are not contaminated with adhesive on the lower door hinge and door check strap on installation. Apply panel bonding adhesive to spot welded/bonded areas as indicated. Use the bond path shown in the graphic as a guide, the panel bond adhesive must only be applied in the areas where spot welding is accessible for the installation of the new panel. It is not to be applied in any areas of MIG welding/brazing installation joints, leave a 30mm gap, so it does not affect the MIG weld/braze joint on installation.

Range Rover Evoque. Side Panel Sheet Metal Repairs - 5-Door

9. Apply sealer adhesive to the upper and lower NVH components.

10. Offer up the new panel and clamp into position. Check alignment, if correct, proceed to next step, if not, rectify and recheck before proceeding.

11. NOTE: This joint must be MIG brazed due to the boron reinforcement

Tack MIG braze the upper butt joint.

12. NOTE: This joint must be MIG brazed due to the boron reinforcement

Tack MIG braze the lower butt joint.

13. NOTE: Make sure that spot welds are installed at least 5mm away from existing spot welds on underlying panels.

Spot weld.

Range Rover Evoque. Side Panel Sheet Metal Repairs - 5-Door

14. MIG plug weld.

15. MIG braze the slots.

16. NOTE: These joints must be MIG brazed due to boron reinforcements. MIG braze the upper and lower butt joints.

Range Rover Evoque. Side Panel Sheet Metal Repairs - 5-Door

17. Dress all welds.

18. NOTE: After this repair wax injection of the repaired areas must be carried out. Seal panel flange edges in the MIG braze slot areas of the door apertures to prevent water ingress.

19. NOTE: After this repair wax injection of the repaired areas must be carried out. Edge sealing of the front flange of the A-pillar outer above the fluting must be carried out to prevent water ingress.

20. NOTE: Make sure all underbody joints are sealed following this repair procedure

The installation of associated panels and mechanical components is the reverse of removal.

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