Freelander Body Repair Manual — part 12
INFORMATION
2
BODY REPAIRS
Straightening
Whenever possible, structural members should be
cold straightened under tension. Do not attempt to
straighten with a single pull but rework the damaged
area using a series of pulls, releasing tension
between each stage and using the opportunity to
check alignment.
Body jig
Unless damage is limited to cosmetic panels, all
repair work to body members must be carried out on
a body jig, to ensure that impact damage has not
spread into more remote parts of the structure.
Mounting on a jig will also ensure that the
straightening and panel replacement procedures do
not cause further distortion.
If original dimensions cannot be satisfactorily
restored by these methods, damaged structural
members should be replaced. Damaged areas
should be cut away using a high speed saw, NOT an
oxy-acetylene torch.
As a rule, body dimensions are symmetrical about
the centre line. A good initial check for distortion is
therefore to measure diagonally and to investigate
apparent differences in dimensions.
Inspection
Every accident produces individual variations in
damage. Each repair is influenced by the extent of
the damage and the facilities and equipment
available for its rectification.
Most accident damage can be visually inspected
and the approximate extent of damage assessed.
Sometimes deformation will extend beyond the
directly damaged area, and the severity of this must
be accurately established so that steps can be taken
to restore critical body components to their original
dimensions. An initial check can be carried out by
means of drop checks or, preferably, trammels.
Gauges are available which will accurately check for
body twist.
INFORMATION
BODY DIMENSIONS
1
DIMENSIONAL INFORMATION
The following dimensional information is shown so
as to assist the technician in the diagnosis and
repair of body panels. The information is shown in
two different ways. There are X,Y,Z dimensions and
actual point to point dimensions.
The X,Y,Z dimensions are the measuring planes
used within Rover Group for the measurement of
body panels. The whole bodyshell is within a parallel
grid system.
The X plane is an imaginary vertical line starting at
the front of the vehicle. It is parallel to the body and
measures the length of the vehicle.
The Y plane is an imaginary line through the center
of the vehicle. All Y dimensions start from this line.
As a rule, body dimensions are symmetrical about
the centre line.
The Z plane is set at a fixed distance parallel and
perpendicular to the underside of the vehicle. All Z
dimensions start from this plane.
The point to point measurements are actual
distances between two points. These points can be
holes or intersection points. Where holes are taken,
the point of measurement is always from the hole
centre.
All measurements shown are in millimetres.
INFORMATION
2
BODY DIMENSIONS
Underbody dimensional information (see following Figure)
No.
Description
X
Y
Z
1
Front sidemember, jig location hole
420
481
314
2
Front crossmember, jig location hole
340.5
350
170
3
Front damper, inboard fixing hole
975.5
515
693.5
4
Front subframe, front fixing
1036
386
98
5
Front subframe, rear outboard fixing
1326
429.5
127
6
Reinforcement outrigger, datum hole
1326
330
127
7
Front production location hole
1395
535
125
8
Trailing link fixing, centre hole
2765
463
160
9
Rear longitudinal, front jig location hole 2900
432
131.5
10
Rear subframe, front fixing
3302
465
274.5
11
Rear damper, rear fixing
3636
610
728.5
12
Rear subframe, rear fixing
3671.5
515
305
13
Rear longitudinal, rear jig location hole
4000
527
305
14
Rear production location hole
4122.5
410
301
INFORMATION
BODY DIMENSIONS
3
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