L322 Range Rover Service Procedures
GENERAL INFORMATION
03-32
Body Repairs
General
Unlike previous Range Rovers that had a body shell
bolted to a chassis frame, the new Range Rover has
a steel monocoque body. This new monocoque
construction gives significant improvements in
torsional rigidity and bending stiffness. Front, side
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
repair.
Repairs usually involve a combination of operations
ranging from straightening procedures to renewal of
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 the vehicles' downtime,
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. The objective is to restore the vehicle
to a safe running condition by carrying out a repair
which is as close as is feasible to original standard.
The results should not advertise to the experienced
eye that the vehicle has been damaged, although the
repair might not be identical in all respects to the
original factory build. Commercial bodyshop 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. Where
necessary a road test of the vehicle should be 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 where 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 and associated wiring. Where
necessary, refer to the relevant section of this
Workshop Manual for removal and refitting
instructions.
Taking into consideration the differences in body
styles, suspension systems, engine and
transmission layouts, the location of the following
components as applicable to a particular vehicle is
critical:
l
Front suspension upper damper mountings.
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Sub frame mountings and additional front
suspension mounting points.
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Engine mountings.
l
Rear suspension upper damper mountings.
l
Rear suspension mountings or lower pivots.
Additional points which can be used to check
alignment and assembly are:
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Inner holes in cross member - side - main floor.
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Holes in front bulkhead.
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Holes in rear longitudinals.
l
Holes in rear lower panels.
Apertures for windscreen, rear screen, bonnet and
doors can be measured and checked using the
dimensional information provided and also by
offering up an undamaged component as a gauge.
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.
