Land Rover Range Rover Body Repair Rover Manual

							GENERAL SPECIFICATION DATA
5
INFORMATION FUEL HANDLING PRECAUTIONS
The following information provides basic precautions
which must be observed if fuel is to be handled safely.
It also outlines the other areas of risk which must not
be ignored.
This information is issued for basic guidance only, and
in any case of doubt, appropriate enquiries should be
made of your local Fire Officer or Fire Department.
Fuel vapor is highly flammable and in confined spaces
is also very explosive and toxic.
When fuel evaporates it produces 150 times its own
volume in vapor, which when diluted with air becomes
a readily ignitable mixture. The vapor is heavier than
air and will always fall to the lowest level. It can readily
be distributed throughout a workshop by air current,
consequently, even a small spillage of fuel is very
dangerous.
Always have a fire extinguisher containingFOAM CO
2
GAS,orPOWDERclose at hand when handling fuel,
or when dismantling fuel systems and in areas where
fuel containers are stored.
WARNING: lt is imperative that the battery
is not disconnected during fuel system
repairs as arcing at the battery terminal
could ignite fuel vapour in the atmosphere.
Always disconnect the vehicle battery BEFORE
carrying out work on the fuel system.
Whenever fuel is being handled, transferred or
stored, or when fuel systems are being dismantled
all forms of ignition must be extinguished or
removed, any leadlamps used must be flame proof
and kept clear of spillage.
No one should be permitted to repair components
associated with fuel without first having had fuel
system training.Hot fuel handling precautions
WARNING: Before commencing any
operation requiring fuel to be drained from
the fuel tank, the following procedure must
be adhered to:
1.Allow sufficient time for the fuel to cool, thus
avoiding contact with hot fuels.
2.Vent the system by removing the fuel filler cap in
a well ventilated area. Refit the filler cap until the
commencement of fuel drainage.
Fuel transfer
WARNING: Fuel must not be extracted or
drained from any vehicle while it is
standing over a pit.
The transfer of fuel from the vehicle fuel tank must be
carried out in a well ventilated area. An approved
transfer tank must be used according to the transfer
tank manufacturers instructions and local regulations,
including attention to grounding of tanks.
Fuel tank removal
AFUEL VAPOURwarning label must be attached to
the fuel tank upon removal from the vehicle.
Fuel tank repair
Under no circumstances should a repair to any tank
be attempted. 
						

							04GENERAL SPECIFICATION DATA NEW RANGE ROVER
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INFORMATION ELECTRICAL PRECAUTIONS
General
The following guidelines are intended to ensure the
safety of the operator whilst preventing damage to the
electrical and electronic components fitted to the
vehicle. Where necessary specific precautions are
detailed in the relevant sections of this Manual which
should be referred to prior to commencing repair
operations.
Equipment - Prior to commencing any test procedure
on the vehicle ensure that the relevant test equipment
is working correctly and any harness or connectors
are in good condition. This particularly applies to
mains lead and plugs.
WARNING: Before commencing work on
an ignition system all high tension
terminals, adaptors and diagnostic
equipment for testing should be inspected to
ensure that they are adequately insulated and
shielded to prevent accidental personal contacts
and minimise the risk of shock. Wearers of
surgically implanted pacemaker devices should
not be in close proximity to ignition circuits or
diagnostic equipment.
Polarity - Never reverse connect the vehicle battery
and always observe the correct polarity when
connecting test equipment.
High Voltage Circuits - Whenever disconnecting live ht
circuits always use insulated pliers and never allow
the open end of the ht lead to come into contact with
other components, particularly ECUs. Exercise
caution when measuring the voltage on the coil
terminals while the engine is running, as high voltage
spikes can occur on these terminals.
Connectors and Harness - The engine compartment
of a vehicle is a particularly hostile environment for
electrical components and connectors. Always ensure
these items are dry and oil free before disconnecting
and connecting test equipment. Never force
connectors apart either by using tools or by pulling on
the wiring harness. Always ensure locking tabs are
disengaged before removal and not orientation to
enable correct reconnection. Ensure that any
protective covers and substances are replaced if
disturbed.Having confirmed a component to be faulty, switch off
the ignition and disconnect the battery. Remove the
component and support the disconnected harness.
When replacing the component keep oily hands away
from electrical connection areas and push connectors
home until any locking tabs fully engage.
Battery disconnecting
Before disconnecting the battery, switch off all
electrical equipment. If the radio is to be serviced,
ensure the security code has been deactivated.
CAUTION: To prevent damage to electrical
components ALWAYS disconnect the
battery when working on the vehicle
electrical system. The earth lead must be
disconnected first and reconnected last. Always
ensure that battery leads are routed correctly and
are not close to any potential chafing points.
Battery charging
Recharge the battery out of the vehicle and keep the
top well ventilated. While being charged or
discharged, and for approximately fifteen minutes
aferwards, batteries emit hydrogen gas. This gas is
inflammable.
Always ensure any battery charging is well ventilated
and that every precaution is taken to avoid naked
flames and sparks. 
						

							GENERAL SPECIFICATION DATA
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INFORMATION Jump starting
WARNING: Hydrogen and oxygen gases
are produced during normal battery
operation. This gas mixture can explode if
flames, sparks or lighted tobacco are brought
near battery. When charging or using a battery in
an enclosed space, always provide ventilation and
shield your eyes.
Keep out of reach of children. Batteries contain
sulphuric acid. Avoid contact with skin, eyes, or
clothing. Also, shield eyes when working near
battery to protect against possible splashing of
acid solution. In case of acid contact with skin,
eyes, or clothing, flush immediately with water for
a minimum of fifteen minutes. If acid is swallowed,
drink large quantities of milk or water, followed by
milk of magnesia, a beaten egg, or vegetable oil.
SEEK MEDICAL AID IMMEDIATELY.
To Jump Start - Negative Ground Battery
WARNING: To avoid any possibility of
injury use particular care when connecting
a booster battery to a discharged battery.
1.Position vehicles so that jump leads will reach,
ensuring that vehiclesDO NOT TOUCH,
alternatively a fully charged slave battery may be
positioned on floor adjacent to vehicle.
2.Ensuring that ignition and all electrical
accessories are switched off, that parking brake
is applied and neutral is selected on a manual
gearbox, with an automatic gearbox select
neutral (N) or park (P) and then connect the
jump leads as follows;
A.Connect one end of first jumper cable to positive
(+) terminal of booster battery.
B.Connect other end of first jumper cable to
positive (+) terminal of discharged battery.
C.Connect one end of second jumper cable to
negative terminal of booster battery.
D.Connect other end of second jumper cable to a
good earth point on the engine,NOT TO
NEGATIVE TERMINAL OF DISCHARGED
BATTERY.Keep jumper lead away from moving
parts, pulleys, drive belts and fan blade
assembly.
WARNING: Making final cable connection
could cause an electrical arc which if
made near battery could cause an
explosion. 
						

							04GENERAL SPECIFICATION DATA NEW RANGE ROVER
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INFORMATION 3.If booster battery is installed in another vehicle,
start engine and allow to idle.
4.Start engine of vehicle with discharged battery,
following starting procedure in Owners Manual.
CAUTION: If vehicle fails to start within a
maximum time of 12 seconds, switch
ignition off and investigate cause. Failing
to follow this instruction could result in
irrepairable damage to catalysts.
5.Remove negative (-) jumper cable from the
engine and then terminal of booster battery.
6.Remove positive (+) jumper cable from positive
terminals of booster battery and discharged
battery.Disciplines
Switch off ignition prior to making any connection or
disconnection in the system as electrical surge
caused by disconnecting live connections can
damage electrical components.
Ensure hands and work surfaces are clean and free of
grease, swarf, etc. as grease collects dirt which can
cause tracking or high-resistance contacts.
When handling printed circuit boards, treat them as
you would a disc - hold by the edges only; note that
some electronic components are susceptible to body
static.
Connectors should never be subjected to forced
removal or refit, especially inter-board connectors, as
damaged contacts will cause short circuit and
open-circuit conditions.
Prior to commencing test, and periodically during test,
touch a good earth (i.e. cigar lighter socket) to
discharge body static as some electronic components
are vulnerable to static electricity.
Grease for electrical connectors
All underbonnet and underbonnet connectors are
protected against corrosion by the application of a
special grease on production. Should connectors be
disturbed in service, repaired or replaced, a grease of
this type (available in 150gm tubes under Part No.
BAU 5811) should again be applied.
NOTE: The use of other greases must be
avoided as they can migrate into relays,
switches etc., contaminating the contacts
and leading to intermittent operation or failure. 
						

							GENERAL SPECIFICATION DATA
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INFORMATION BODY REPAIRS
Body shells are of welded construction and bolted to
the chassis frame. Front 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 or
chassis repair.
Repairs usually involve a combination of operations
ranging from straightening procedures to renewal of
either 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 vehicles down-time,
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 with the
objective of restoring the vehicle to a safe running
condition and effecting a repair which is visually
acceptable and which, even to the experienced eye,
does not advertise the fact that it has been damaged.
This does not necessarily mean that the repaired
vehicle will be identical in all respects with original
factory build. 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 and if necessary a
road test of the vehicle is 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 when 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 as well as associated wiring.See
BODY and SRS sections. 
						

							04GENERAL SPECIFICATION DATA NEW RANGE ROVER
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INFORMATION Taking into consideration the differences in body
styles, steering and suspension systems as well as
engine and suspension layouts, the location of the
following components as applicable to a particular
vehicle is critical:
·Front suspension upper damper
mountings.
·Front suspension or sub frame mountings.
·Engine mounting on RH and LH chassis
longitudinals.
·Rear suspension upper damper mountings.
·Rear suspension mountings or lower
pivots.
·Steering rack mountings.
Additional points which can be used to check
alignment and assembly are:
·Inner holes in crossmember - side - main
floor.
·Holes in front longitudinals.
·Holes in extension - side member - front.
·Holes in rear longitudinals.
·Holes in rear lower panels or extension
rear floor.
·Fuel tank mountings.
Apertures for windscreen, backlight, bonnet and doors
can best be checked by offering up an undamaged
component as a gauge. 
						

							GENERAL SPECIFICATION DATA
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INFORMATION JACKING
The following instructions must be carried out before
raising the vehicle off the ground.
1.Use a solid level ground surface.
2.Apply parking brake.
3.Select P or 1st gear in main gearbox.
4.Select Low range in transfer gearbox.
CAUTION: To avoid damage occurring to
the under body components of the vehicle
the following jacking procedures must be
adhered to.
DO NOT POSITION JACKS OR AXLE STANDS
UNDER THE FOLLOWING COMPONENTS.
Body structure Air suspension pipes
Bumpers Fuel lines
Brake lines Front radius arms
Panhard rod Steering linkage
Rear Trailing links Fuel tank
Engine sump Gearbox bell housing
CAUTION: If supporting vehicle by the
front crossmember, the safety stands
must be postioned carefully to avoid
damage to air suspension pipes.Vehicle jack
The jack provided with the vehicle is only intended to
be used in an emergency, for changing a tyre. Do
NOTuse the jack for any other purpose. Refer to
Owners Manual for vehicle jack location points and
procedure. Never work under a vehicle supported by
the vehicle jack.
Hydraulic jack
A hydraulic jack with a minimum 1500 kg, 3,300 lbs
load capacity must be used.
CAUTION: Do not commence work on the
underside of the vehicle until suitable axle
stands have been positioned under the
axle.
Raise the front of the vehicle
1.Position cup of hydraulic arm under differential
casing.
NOTE: The differential casing is not
central to the axle. Care should be taken
when raising the front road wheels off the
ground as the rear axle has less sway stiffness. 
						

							04GENERAL SPECIFICATION DATA NEW RANGE ROVER
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INFORMATION
2.Raise front road wheels to enable an axle stand
to be installed under left hand axle tube.
3.Position an axle stand under right hand axle
tube, carefully lower jack until axle sits securely
on both axle stands, remove trolley jack.
4.Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5.Reverse procedure when removing vehicle from
stands.
Raise rear of vehicle
1.Position cup of hydraulic arm under differential
casing.
2.Raise vehicle to enable axle stands to be
installed under left and right hand axle tubes.3.Lower jack until axle sits securely on axle
stands, remove trolley jack.
4.Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5.Reverse procedure when removing vehicle from
stands. 
						

							GENERAL SPECIFICATION DATA
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INFORMATION HYDRAULIC VEHICLE RAMP (FOUR POST)
Use only a drive on type ramp which supports vehicle
by its own road wheels. If a wheel-free condition is
required, use a drive on ramp incorporating a
wheel-free system that supports under axle casings.
Alternatively, place vehicle on a firm, flat floor and
support on axle stands.
TWO POST VEHICLE RAMPS
The manufacturer of RANGE ROVER VEHICLES
DOES NOT recommend using Two Post ramps
that employ four adjustable support arms. These
are NOT considered safe for Range Rover
vehicles.
If vehicle is installed on a Two Post ramp
responsibility for safety of vehicle and personnel
performing service operations is in the hands of
the Service Provider.DYNAMOMETER TESTING - VEHICLES WITH
ANTI-LOCK BRAKES (ABS)
WARNING: Do not attempt to test ABS
function on a dynamometer
Four wheel dynamometers
NOTE: Before testing a vehicle on a four
wheel dynamometer disconnect the valve
relay.
See Electrical Trouble Shooting
Manual.
The ABS function will not work, the ABS warning
light will illuminate. Normal braking will be
available.
Provided that front and rear rollers are rotating at
identical speeds and that normal workshop safety
standards are applied, there is no speed restriction
during testing except any that may apply to the tyres.
Two wheel dynamometers
IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.
NOTE: ABS will not function on a two
wheel dynamometer. The ABS light will
illuminate during testing. Normal braking
will be available.
If brake testing on a single rig is necessary it must be
carried out with propeller shaft to the rear axle
removed, AND neutral selected in BOTH main and
transfer boxes.
If checking engine performance, the transfer box must
be in high range and drive shaft to stationary axle
removed. 
						

							04GENERAL SPECIFICATION DATA NEW RANGE ROVER
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INFORMATION EMERGENCY TOWING
CAUTION: The New Range Rover has
permanent four-wheel drive. The following
instructions must be adhered to when
towing:-
Towing the vehicle on four wheels
If it is necessary to recover the vehicle by towing on
all four wheels, Transfer neutralMUSTbe selected.
1.With the starter key removed, insert a fuse of 5
amps or more in fuse position 11 in the RH seat
fuse box.
2.Turn the starter switch to position 2; the transfer
box will now automatically select neutral.
3.Wait until the message centre displays
TRANSFER NEUTRAL and then turn the
starter switch off, position 0.
4.Turn the starter switch to position 1 to unlock
the steering and leave in this position while the
vehicle is being towed.
5.Secure tow rope to the front towing eye.
6.Release the parking brake.
CAUTION: The brake servo and power
assisted steering system will not be
functional without the engine running.
Heavier pedal pressure will be required to apply
the brakes, the steering system will require
greater effort to turn the front wheels.
The vehicle tow connection should be used only
in normal road conditions.
CAUTION: DO NOT remove the starter key
or turn the switch to position 0 when the
vehicle is in motion.
7.To reactivate the transfer box after towing, turn
the starter switch off to position 0 and remove
the fuse from position 11. On automatic
vehicles the transfer box will automatically
engage the Low or High gear range.
8.On manual vehicles, first press the range
change switch. The transfer box will then engage
the Low or High gear range.
Suspended tow by breakdown vehicle
CAUTION: To prevent vehicle damage,
front or rear propeller shaft MUST be
removed, dependant upon which axle is
being trailed.
9.To facilitate reassembly, first mark the propeller
shaft drive flanges at transfer box and axle.
10.Remove propeller shaft fixings and lift shaft from
vehicle.
11.If the front axle is to be trailed turn ignition key to
position 1 to release the steering lock.
CAUTION: If the rear axle is to be raised,
the steering wheel and/or linkage MUST be
secured in a straight ahead position. DO
NOT use the steering lock for this purpose.