Land Rover Range Rover Body Repair Rover Manual

Body Repair Manual
DEFENDER 

01
04
60
75
76
77
Body Repair Manual
NEW RANGE ROVER
This manual covers vehicles from
introduction 1995
01 INTRODUCTION
04 GENERAL SPECIFICATION DATA
60 FRONT SUSPENSION
75 SUPPLEMENTARY RESTRAINT SYSTEM
76 CHASSIS AND BODY
77 PANEL REPAIRS
Published by Rover Technical Communication
P O Box 47, Cowley, OXFORD, OX45NL
Ó1996 Rover Group Limited
Publication part no. LRL 0085ENG 

INTRODUCTION
1
INFORMATION INTRODUCTION
This Body Repair Manual is designed to provide the
experienced bodyshop technician with the information
required to carry out efficient and cost effective
repairs.
To assist in the use of this Manual, the section title is
given at the top and the relevant sub-section at the
bottom of each page.
The individual items comprising operations are to be
followed in the sequence in which they appear, see
BODYandSRSsections. Items numbers in the
illustration are referred to...

01INTRODUCTION NEW RANGE ROVER
2
INFORMATION SPECIFICATION
Land Rover are constantly seeking to improve the
specification, design and production of their vehicles
and alterations take place accordingly. While every
effort has been made to ensure the accuracy of this
Manual, it should not be regarded as an infallible
guide to current specifications of any particular
vehicle.
This Manual does not constitute an offer for sale of
any particular vehicle. Land Rover dealers are not
agents of Land Rover and...

INTRODUCTION
1
BODY DIMENSIONS ALIGNMENT JIG DIMENSIONS
1. 1190mm (46.8in.)
2. 1709mm (67.3in.)
3. 2527mm (99.6in.)
4. 4173mm (164.4in.)
5. 717mm (28.3in.)
6. 982.5mm (38.7in.)
7. 1328mm (52.3in.)
8. 1697mm (66.9in.)
9. 3159mm (124.5in.)
10. 1340mm (52.8in.)
11. 1302mm (51.3in.)
12. 665mm (26.2in.)13. 1400mm (55.2in.)
14. 2364mm (93.1in.)
15. 1803mm (71.0in.)
A = No. 1 body mount RH and LH
B = Front spring seat RH and LH
C = No. 2 body mount RH and LH
D = Front crossmember piercing RH and LH
E = Front...

01INTRODUCTION NEW RANGE ROVER
2
BODY DIMENSIONS 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...

GENERAL SPECIFICATION DATA
1
INFORMATION VEHICLE IDENTIFICATION NUMBER (VIN)
An adhesive label containing the Vehicle Identification
Number and the recommended maximum vehicle
weights is located on the left hand side of the bonnet
locking platform.
The number is also stamped on the right side of the
chassis forward of the spring mounting turret.
Key to Vehicle Identification Number Plate
A. VIN (17 digits)
B. Maximum permitted laden weight for vehicle
C. Maximum vehicle and trailer weight
D. Maximum road...

04GENERAL SPECIFICATION DATA NEW RANGE ROVER
2
INFORMATION LOCATION OF IDENTIFICATION NUMBERS
Engine serial number - V8 engine
Stamped on a cast pad on the cylinder block, between
numbers 3 and 5 cylinders.
NOTE: The engine compression ratio is
stamped above the serial number.
Engine serial number - BMW Diesel engine
Stamped on the LH side of the cylinder block above
the sump.Main gearbox R380 - 5 speed
Stamped on a cast pad on the bottom right hand side
of the gearbox.
Automatic gearbox ZF4HP22
Stamped...

GENERAL SPECIFICATION DATA
3
INFORMATION Transfer gearbox-Borg Warner
Stamped on a plate attached to the gearbox casing,
between filler/level and drain plug.
Front and rear axle
Stamped on the left hand axle tubes.Vehicle identification number (VIN)
Made up of 17 digits, these numbers are used to
identify manufacturer, model range, specification,
body type, engine, transmission/steering, model year,
plant and build sequence number and serve to identify
the vehicle.
This example shows the sequence:...

04GENERAL SPECIFICATION DATA NEW RANGE ROVER
4
INFORMATION SAFETY INSTRUCTIONS
Jacking
The recommended jacking points are given in
LIFTING AND TOWING.Always ensure that any lifting
apparatus has adequate load and safety capacity for
the weight to be lifted. Ensure the vehicle is standing
on level ground prior to lifting or jacking. Apply the
handbrake and chock the wheels.
Never rely on a jack as the sole means of support
when working beneath the vehicle. Use additional
safety supports beneath the...