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 in the text. Adjustment and
repair operations include reference to Service Tool
numbers. Each adjustment or repair operation is given
its Service Repair Operation number.
The repair operations cover replacement of the
relevant welded panels and panel assemblies on the
vehicle, seePANEL REPAIRS. The sequence of
operations progresses from the front to the rear of the
vehicle. Each operation details any special points to
observe when replacing a welded panel, together with
cross-references to the relevant trim items to be
removed and replaced for access.
DIMENSIONS
The dimensions quoted are to design engineering
specification with service limits where applicable.REFERENCES
References to the LH or RH side given in this Manual
are made when viewing the vehicle from the rear.
With the engine and gearbox assembly removed, the
water pump end of the engine is referred to as the
front.
WARNINGS, CAUTIONS and NOTES have the
following meanings:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of injury.
CAUTION: Calls attention to procedures
which must be followed to avoid damage
to components.
NOTE: Gives helpful information.
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that Land Rover parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement parts
and accessories: Safety features embodied in the
vehicle may be impaired if other than Land Rover
parts are fitted. In certain territories, legislation
prohibits the fitting of parts not to the vehicle
manufacturers specification. Torque spanner values
given in the Workshop Manual must be strictly
adhered to. Locking devices, where specified, must be
fitted. If the efficiency of a locking device is impaired
during removal it must be replaced with a new one.
Certain fasteners must not be re-used. These
fasteners are specified in the Workshop Manual.
Owners purchasing accessories while travelling
abroad should ensure that the accessory and its fitted
location on the car conform to legal requirements.
The terms of the vehicle Warranty may be invalidated
by the fitting of other than Land Rover recommended
parts.
All Land Rover recommended parts have the full
backing of the vehicle Warranty.
Land Rover dealers are obliged to supply only Land
Rover recommended parts. 
						

							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 have no authority to bind
the manufacturer by any expressed or implied
undertaking or representation. 
						

							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 radius arm mounting bracket RH and LH
F = No. 3 body mount RH and LH
G = Rear composite link mounting bracket RH and
LH
H = No. 5 body mount RH and LH
All dimensions taken at centre line of set screw or set screw hole. 
						

							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 remote parts of the body 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 differences in
damage. Each repair is influenced by the extent of the
damage and by the facilities and equipment available
for its rectification.
Most accident damage can be visually inspected and
the approximate extent of the damage assessed.
Sometimes deformation will extend beyond the area
of direct damage, and the severity of this must be
accurately established so that steps may be taken to
restore critical body components to their original
dimensions.
An initial check of critical dimensions can be carried
out by means of drop checks or (preferably) trammels.
Gauges are available which will check accurately for
body twist. Where repairs necessitate renewal of a
critical body component it is recommended that a
body jig is used. 
						

							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 weight-front axle
E. Maximum road weight-rear axle
In addition the VIN is stamped on a plate which is
visible through the left side of the windscreen.Federal (USA) vehicle identification number
An adhesive label containing the Vehicle Identification
Number, date of manufacture and gross axle weight
ratings is fixed to the lock face of the front left hand
door. The information includes wheel and tyre sizes
and tyre pressures at gross axle weight ratings. 
						

							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 on a plate riveted to the bottom left hand
side of the gearbox casing. 
						

							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:
European code
SALLPAMJ7MA
S Europe
AL UK
LP Range Rover
A European Spec.
M 4 Door Station Wagon
J 4.6 Litre Fuel Injection
7 Manual right steering
M 1995 Model Year
A Solihull
Federal (USA) code
SALPV1242SA
S Europe
AL UK
P Range Rover
V North America Spec.
1 4 Door Station Wagon
2 4.0 Litre fuel injection
4 Automatic, Left Hand Steering
2 Check Digit
S 1995 Model Year
A Solihull 
						

							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 vehicle.
Do not leave tools, lifting equipment, spilt oil, etc.
around or on the work bench area.
Precautions against damage
Always fit wing and seat covers before commencing
work. Avoid spilling brake fluid or battery acid on
paintwork. Wash off with water immediately if this
occurs.
Disconnect the battery earth lead before starting work.
SeeELECTRICAL PRECAUTIONS.
Always use the recommended service tool or a
satisfactory equivalent where specified.
Protect exposed bearing and sealing surfaces and
screw threads from damage.Brake Hydraulics
WARNING: It is imperative that the correct
brake fittings are used and that threads of
components are compatible.
Always use two spanners when slackening or
tightening brake pipe or hose connections. Ensure
that hoses run in a natural curve and are not kinked or
twisted. Fit brake pipes securely in their retaining clips
and ensure that the pipe run cannot contact a
potential chafing point.
Containers used for hydraulic fluid must be kept
absolutely clean. Do not store hydraulic fluid in an
unsealed container; it will absorb water and in this
condition will be dangerous to use. Do not allow
hydraulic fluid to be contaminated with mineral oil, or
use a container which has previously contained
mineral oil. Do not re-use fluid from the system.
Always use clean brake fluid or a recommended
alternative to clean hydraulic components. Fit a
blanking cap to an hydraulic union and a plug to its
socket after removal to prevent the ingress of dirt.
Absolute cleanliness must be observed with hydraulic
components.
Engine coolant caps and plugs
Extreme care is necessary when removing engine
coolant caps and plugs when the engine is hot and
especially if it is overheated. To avoid the possibility of
scalding allow the engine to cool before attempting
coolant cap or plug removal.
Cleaning components
Always use the recommended cleaning agent or
equivalent.
Do not use degreasing equipment for components
containing items which could be damaged by the use
of its process. Whenever possible clean components
and the area surounding them before removal. Always
observe scrupulous cleanliness when cleaning
dismantled components.