Range Rover Evoque: Front Side Member and Suspension Top Mount Assembly

Removal

NOTES:

The front side member and suspension top mount assembly consists of the front side member closing panel, fender apron panel front reinforcement, fender apron lower panel, suspension top mount, and fender apron panel reinforcement.

The panel is serviced less its weld studs

1. In this procedure, to make sure the vehicle is correctly aligned, it must be placed on an approved alignment jig.

2. The front side member and suspension top mount assembly is replaced in conjunction with:

1. Front bumper cover
2. Front bumper
3. Hood latch panel
4. Front fender
5. Front bumper mounting
6. Fender apron upper panel
7. Front side member

3. 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).

4. Remove the front side member.

For additional information, refer to: Front Side Member (501-27 Front End Sheet Metal Repairs, Removal and Installation).

5. Remove the front side member closing panel.

For additional information, refer to: Front Side Member Closing Panel (501-27 Front End Sheet Metal Repairs, Removal and Installation).

6. Remove the fender apron panel reinforcement.

For additional information, refer to: Fender Apron Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation).

7. Remove the suspension top mount.

For additional information, refer to: Suspension Top Mount (501-27 Front End Sheet Metal Repairs, Removal and Installation).

8. Release and lay aside the insulating material at the outer bulkhead.

9. Release and lay aside the wiring harnesses at the a-pillar, bulkhead and side member.

10. This procedure details the missing joints between the front side member closing, suspension top mount, fender apron panel reinforcement and the front side member to make up the front side member and suspension top mount assembly replacement method.

11. NOTE: Where access is limited use a belt sander to sand down the spot welds in these areas. Drill out the spot welds.

12. Separate the joints and remove the old panel.

Installation

1. Prepare the new panel in the areas where it is not fully welded and spot weld.

2. 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.

3. Remove the new panel.

4. NOTE: All other MIG plug welds are catered for in the front side member, front side member closing and suspension top mount procedures. Using the removed front side member closing and suspension top mount as a guide, drill holes in the new panel as required ready for MIG plug welding.

5. Prepare the old and new panel joint surfaces.

6. 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. NOTE: MIG plug welds can be substituted for spot welds if access is insufficient. Spot weld and MIG plug weld where required.

8. Refer to the front side member closing, suspension top mount, fender apron panel reinforcement and the front side member procedures to complete this installation.

9. Dress all welded joints.

10. LH Only.

Prepare the new panel and install the weld studs in their original locations. The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

11. RH Only.

Prepare the new panel and install the weld studs in their original locations. The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

12. Refer to the following procedures for the installation of the remaining weld studs.

For additional information, refer to: Fender Apron Lower Panel (501-27 Front End Sheet Metal Repairs, Removal and Installation) / Fender Apron Panel Front Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation) / Front Side Member Closing Panel (501-27 Front End Sheet Metal Repairs, Removal and Installation) / Suspension Top Mount (501-27 Front End Sheet Metal Repairs, Removal and Installation) / Front Side Member (501-27 Front End Sheet Metal Repairs, Removal and Installation).

13. Apply a zinc rich primer to any bare metal surfaces at this stage.

14. 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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