Range Rover Body Repair Manual — part 4
GENERAL SPECIFICATION DATA
9
INFORMATION
BODY REPAIRS
Body shells are of welded construction and bolted to
the chassis frame. Front and rear sections of the shell
are designed as ’energy absorbing’ zones. This
means they are designed to deform progressively
when subjected to impact in order to minimise the
likelihood of injury to vehicle occupants.
It is essential that design dimensions and strength are
restored in accident rectification. It is important that
neither structural weakness nor excessive local
stiffness are introduced into the vehicle during body or
chassis repair.
Repairs usually involve a combination of operations
ranging from straightening procedures to renewal of
either individual panels or panel assemblies. The
repairer will determine the repair method and this
decision will take into account a balance of economics
between labour and material costs and the availability
of repair facilities in both equipment and skills. It may
also involve considerations of vehicles down-time,
replacement vehicle availability and repair turn-around
time.
It is expected that a repairer will select the best and
most economic repair method possible, making use of
the facilities available. The instructions given are
intended to assist a skilled body repairer by expanding
approved procedures for panel replacement with the
objective of restoring the vehicle to a safe running
condition and effecting a repair which is visually
acceptable and which, even to the experienced eye,
does not advertise the fact that it has been damaged.
This does not necessarily mean that the repaired
vehicle will be identical in all respects with original
factory build. Repair facilities cannot always duplicate
methods of construction used during production.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and suspension
geometry checked after completion and if necessary a
road test of the vehicle is carried out, particularly
where safety related items are concerned.
Where major units have been disconnected or
removed, it is necessary to ensure that fluid levels are
checked and topped up when necessary. It is also
necessary to ensure that the repaired vehicle is in a
roadworthy condition in respect of tyre pressures,
lights, washer fluid etc.
Body repairs often involve the removal of mechanical
and electrical units as well as associated wiring. See
BODY and SRS sections.
04
GENERAL SPECIFICATION DATA
NEW RANGE ROVER
10
INFORMATION
Taking into consideration the differences in body
styles, steering and suspension systems as well as
engine and suspension layouts, the location of the
following components as applicable to a particular
vehicle is critical:
•
Front suspension upper damper
mountings.
•
Front suspension or sub frame mountings.
•
Engine mounting on RH and LH chassis
longitudinals.
•
Rear suspension upper damper mountings.
•
Rear suspension mountings or lower
pivots.
•
Steering rack mountings.
Additional points which can be used to check
alignment and assembly are:
•
Inner holes in crossmember - side - main
floor.
•
Holes in front longitudinals.
•
Holes in extension - side member - front.
•
Holes in rear longitudinals.
•
Holes in rear lower panels or extension
rear floor.
•
Fuel tank mountings.
Apertures for windscreen, backlight, bonnet and doors
can best be checked by offering up an undamaged
component as a gauge.
GENERAL SPECIFICATION DATA
11
INFORMATION
JACKING
The following instructions must be carried out before
raising the vehicle off the ground.
1. Use a solid level ground surface.
2. Apply parking brake.
3. Select ’P’ or 1st gear in main gearbox.
4. Select Low range in transfer gearbox.
CAUTION: To avoid damage occurring to
the under body components of the vehicle
the following jacking procedures must be
adhered to.
DO NOT POSITION JACKS OR AXLE STANDS
UNDER THE FOLLOWING COMPONENTS.
Body structure
Air suspension pipes
Bumpers
Fuel lines
Brake lines
Front radius arms
Panhard rod
Steering linkage
Rear Trailing links
Fuel tank
Engine sump
Gearbox bell housing
CAUTION: If supporting vehicle by the
front crossmember, the safety stands
must be postioned carefully to avoid
damage to air suspension pipes.
Vehicle jack
The jack provided with the vehicle is only intended to
be used in an emergency, for changing a tyre. Do
NOT use the jack for any other purpose. Refer to
Owner’s Manual for vehicle jack location points and
procedure. Never work under a vehicle supported by
the vehicle jack.
Hydraulic jack
A hydraulic jack with a minimum 1500 kg, 3,300 lbs
load capacity must be used.
CAUTION: Do not commence work on the
underside of the vehicle until suitable axle
stands have been positioned under the
axle.
Raise the front of the vehicle
1. Position cup of hydraulic arm under differential
casing.
NOTE: The differential casing is not
central to the axle. Care should be taken
when raising the front road wheels off the
ground as the rear axle has less sway stiffness.
04
GENERAL SPECIFICATION DATA
NEW RANGE ROVER
12
INFORMATION
2. Raise front road wheels to enable an axle stand
to be installed under left hand axle tube.
3. Position an axle stand under right hand axle
tube, carefully lower jack until axle sits securely
on both axle stands, remove trolley jack.
4. Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5. Reverse procedure when removing vehicle from
stands.
Raise rear of vehicle
1. Position cup of hydraulic arm under differential
casing.
2. Raise vehicle to enable axle stands to be
installed under left and right hand axle tubes.
3. Lower jack until axle sits securely on axle
stands, remove trolley jack.
4. Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5. Reverse procedure when removing vehicle from
stands.
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