Range Rover Classic. Manual — part 145
CHASSIS AND BODY
3
REPAIR
SUBSTRATE
ALUMINIUM PANELS
PANEL REPAIR
REPLACEMENT PANEL
PREPARATION
Wet for using P60 Grade paper or dry sand using
P240 grit discs.
Wet flat using P60 Grade paper or dry sand using
P240 grit discs.
Care must be taken to avoid cutting through to bare
aluminium.
BODY FILLING
If filling is required, thoroughly abrade bare aluminium
area to be filled and apply Standox Polyester
If filling is required, fill small indentations with Standox
Polyster stopper 430-5029.
ETCHING
This process is not required if the original electrocoat
primer is in sound condition.
IF NOT
Etch the bare aluminium and filler with auto-speed self
etch primer 414-1171, mixed 1:1 with activator
801-7995. Apply one coat and allow to dry for
approximately 20 minutes. Recoat within 1 hour.
PRIMING
To obtain maximum adhesion and excellent build, apply
Standox 2K 4:1 full primer 405-0381. Coats of 30-40 microns
can be wet flatted with P60 grade paper after 45 minutes at
20
°
C.
COLOUR COATING
Apply either Standox 2K Standocryl or Standox Metallic
Basislack to the colour required. Hardeners and thinners will
vary depending upon system employed, conditions available,
temperature and size of vehicle etc. Refer to paint
manufacturer’s Technical Information Sheet for correct
selection.
76
CHASSIS AND BODY
4
REPAIR
BODY
Introduction:
The information which follows is concerned solely with
the ’Monocoque’ assembly of the inner body shell on
Range Rover models.
Body repairs often require the removal of mechanical
and electrical units and associated wiring. Where
necessary, reference should be made to the relevant
section of the Repair Manual for removal and refitting
instructions.
The inner body shell is of ’Monocoque’ construction
and to gain access to the repair area, it may be
necessary to remove exterior body panels, all exterior
body panels are bolted to the inner body shell to
facilitate easier panel removal and replacement or
repair.
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 car to a safe running
condition and effecting a repair which is visually
acceptable.
WARNING: After collision damage has
been repaired and the airbags(s) has not
deployed, the SRS integrity must be
confirmed using TestBook.
WELDING
The following charts and illustrations show the
locations and types of weld for securing the body side
assembly, tailgate frame assembly and the front
valance and wheel arch assembly. Before undertaking
any spot weld joints to the inner body, it is advisable
to make a test joint using offcuts of the damaged
components, and to use this test piece to perform a
weld integrity test.
Spot welding is satisfactory if the joints do not pull
apart. If the weld pulls a hole or tears the metal the
weld is satisfactory. It is defective if the weld joint pulls
apart or if there are signs of burning, porosity or
cracking evident.
PREPARATION
Thoroughly clean all areas to be welded, remove any
sealants and corrosion protectives from around
original panels. Align and clamp all new panels in
position and check relationship to one another.
CHASSIS AND BODY
5
REPAIR
INNER BODY SHELL ASSEMBLY
LOCATION
FACTORY JOINT
(minimum number of spot welds quoted)
A.
Front cross member to
6 spot welds, 20mm pitch
valance and wheel arch assembly
B.
Bonnet[hood] locking platform to
10 spot welds, 25mm pitch
valance and wheel arch
assembly
C.
Valance and wheel arch
16 spot welds, 25mm pitch
assembly to dash and tunnel
assembly
D.
Body side complete to dash
10 spot welds, 65mm pitch
and tunnel assembly
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CHASSIS AND BODY
6
REPAIR
LOCATION E
LOCATION F
LOCATION
E.
1. Body side complete to heelboard panel
assembly.
14 spot welds, 35mm pitch
2. Body side complete to dash and tunnel
assembly complete.
10 spot welds, 25mm pitch
3. Body side complete to dash and tunnel
assembly complete.
3 spot welds, 30mm pitch
F.
1. Body side complete to dash and tunnel
assembly complete
7 spot welds, 30mm pitch
2. Body side complete to dash and tunnel
assembly complete
18 spot welds, 40mm pitch
3. Body side complete to dash and tunnel
assembly complete
30 spot welds, 34mm pitch
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