Land Rover Range Rover Body Repair Rover Manual

							GENERAL SPECIFICATION DATA
15
INFORMATION TRANSPORTING THE VEHICLE BY TRAILER
If the vehicle should require transporting on a trailer or
the back of a lorry, the air suspension must be set to
ACCESS before being lashed.
See FRONT
SUSPENSION, Description and operation.
Lashing eyes are provided on the front and rear
chassis cross members to facilitate the securing of the
vehicle, as shown.
CAUTION: DO NOT secure lashing hooks
or trailer fixings to any other part of the
vehicle.
CAUTION: If the air suspension cannot be
set to the ACCESS position, then the
vehicle must be lashed by its wheels and
not the lashing eyes.
Install vehicle on the trailer and apply park brake.
Select neutral in main gearbox; this will prevent
damage to the parking pawl of the automatic gearbox. 
						

							04GENERAL SPECIFICATION DATA NEW RANGE ROVER
16
INFORMATION VEHICLE DIMENSIONS
mm inches
Overall length 4713................................................................... 185.6
with Europe/UK towbar 4804........................................... 189.1
Overall width 1889.................................................................... 74.4
Overall height at standard profile 1817.5..................................... 71.6
Wheelbase 2745....................................................................... 108.1
Track:
Front 1540........................................................................ 60.6
Rear 1530........................................................................ 60.2
Turning circle between kerbs 1189 mm (39 ft)...........................................
STEERING
Power steering box
Make/type ZF type 8055, recirculating ball steering gear........................................................................
Steering wheel turns, lock-to-lock 3.2....................................
Steering pump
Make/type:
V8 engine ZF type 7691, vane type................................................................
Diesel engine ZF type7681, vane type..........................................................
Steering geometry
Steering wheel diameter 406.4mm (16 in.)..................................................
Toe-out measurement 0.6 to 1.80mm (0.02 - 0.07 in.)......................................................
Toe-out included angle 0Ê 5 to 0Ê 15.....................................................
Camber angle 0Ê..................................................................NOTE:
Castor angle 4Ê.....................................................................Check at
Swivel pin inclination static 8Ê...............................................kerbweight 
						

							GENERAL SPECIFICATION DATA
17
INFORMATION VEHICLE WEIGHTS AND PAYLOAD
When loading a vehicle to its maximum (Gross Vehicle Weight), consideration must be taken of the vehicle kerb
weight and the distribution of the payload to ensure that axle loadings do not exceed the permitted maximum
values. It is the customers responsibility to limit the vehicles payload in an appropriate manner such that neither
maximum axle loads nor Gross Vehicle Weight are exceeded.
GROSS VEHICLE WEIGHT
Petrol Models Diesel Models
Front Axle 1320 kg (2910 lb).............................. 1320 kg (2910 lb).............
Rear Axle 1840 kg (4056 lb).............................. 1840 kg (4056 lb).............
Total 2780 kg (6129 lb)...................................... 2780 kg (6129 lb).............
Maximum Payload 603 kg (1329 lb)................. 596 kg (1314 lb)...............
EEC KERB WEIGHT AND DISTRIBUTION
4.0 Litre Manual 4.0 Litre Automatic 4.6 Litre Automatic
EEC Kerb Weight 2090 kg (4607 lb).................. 2100 kg (4629 lb)............. 2220 kg (4894 lb).............
Front Axle 1095 kg (2414 lb).............................. 1100 kg (2425 lb)............. 1165 kg (2568 lb).............
Rear Axle 995 kg (2193 lb).............................. 1000 kg (2204 lb)............... 1055 kg (2325 lb).............
2.5 Diesel Manual 2.5 Diesel Automatic
EEC Kerb Weight 2115 kg (4662 lb).................. 2130 kg (4695 lb).............
Front Axle 1110 kg (2447 lb).............................. 1120 kg (2469 lb).............
Rear Axle 1005 kg (2215 lb).............................. 1010 kg (2226 lb).............
NOTE: EEC KERB WEIGHT is the minimum vehicle specification plus full fuel tank and 75 kg
(165lb) driver.
NOTE: GROSS VEHICLE WEIGHT is the maximum all-up weight of the vehicle including driver,
passengers, and equipment. This figure is liable to vary according to legal requirements in certain
countries.
NOTE: MAXIMUM ROOF RACK LOAD (including weight of rack) 75 kg (165 lb) must be included in
total vehicle weight. 
						

							GENERAL SPECIFICATION DATA
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. 
						

							04GENERAL SPECIFICATION DATA 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
COMPONENT LOCATION ELECTRONIC CONTROL UNITS
1. Engine control module (ECM) (at RH of engine
bay)
2. ABS ECU (behind access plate at LH of
dashboard)
3. Cruise control ECU (behind fascia closing panel)4. Diagnostic control unit (on centre tunnel)
5. Electronic suspension ECU (beneath LH front
seat)
6. Body electrical control module (BeCM) (beneath
RH front seat)
The electronic control units fitted to Land Rover
vehicles make it advisable to follow suitable
precautions prior to carrying out welding repair
operations. Harsh conditions of heat and vibration
may be generated during these operations which
could cause damage to the units.See ELECTRICAL
PRECAUTIONS section.
In particular, it is essential to follow the appropriate
precautions when disconnecting or removing the SRS
diagnostic unit.See SUPPLEMENTARY RESTRAINT
SYSTEM, Precautions section. 
						

							GENERAL SPECIFICATION DATA
1
SEALING AND CORROSION PROTECTION APPROVED MATERIALS
MATERIAL MANUFACTURER
3M:
Bodygard (08158, 08159)
Weld Thru Sealer (08625)
Drip-Chek Clear (08401)
Drip-Chek Heavy (08531)
Flexseal Polyurethane Seam Sealer (08684, 08689, 08694)
Polyurethane Sealer (sachet) (08703, 08783, 08788)
Super Seam Sealer (08537)
Sprayable Sealer (08800, 08823)
Bolted Panel Sealer (08572)
Body Caulking (08568)
Windscreen Sealer (08509)
Gurit-Essex:
Betafill Clinch and Brushable Sealer (Black) (10215)
Betafill Clinch and Brushable Sealer (Grey) (10211)
Betafill Clinch and Brushable Sealer (White) (10220)
Clinch Joint and Underbody Coating (Grey) (10101)
Clinch Joint and Underbody Coating (Beige) (10707)
SEALERS Kent Industries:
Leak-Chek Clear Putty (10075)
PPG:
Polyurethane Seam Sealer (6500)
Polyurethane Seam Sealer (92)
Terostat Preformed Strip (V11)
Terolan Light Seam Sealer
Teroson:
Terolan Special Brushable Seam Sealer
Terostat 1K PU Seam Sealer (SE20)
Terostat Sprayable Seam Sealer (9320)
Unipart:
Promatch Sealing Compound (UBS605, UBS606, UBS607)
Promatch Bolted Panel Sealer (UBS111)
Wurth:
Sealing Compound (890100, 890101, 890102, 890103, 890104,
890105, 890106)
Astrolan Engine Bay Wax & Cosmetic Wax (DA3241/DA3243)
Weld Thru Coating (05913) 
						

							04GENERAL SPECIFICATION DATA NEW RANGE ROVER
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SEALING AND CORROSION PROTECTION Approved materials (continued)
MATERIAL MANUFACTURER
3M:
Automotive Structural Adhesive (08120)
Aerosol Auto Adhesive (Trim) (08080)
ADHESIVES Spray 80 Adhesive (08090)
Ciba-Geigy:
Structural Two-Part Epoxy (XB5106/XB5107)
3M:
Spray Schutz (08877)
Body Schutz (08861)
Stone Chip Coating (Textured) (08868, 08878, 08879)
Stone Chip Coating (Smooth) (08158, 08160, 08886)
Croda:
Crodapol Brushable Underbody Sealer (PV75)
UNDERBODY COATINGS Underbody Wax (PW61)
Dinol:
Tectacote Underbody Wax (205)
Teroson:
Terotex Underseal CP02 (9320)
Unipart:
Promatch Underbody Schutz (UBS410)
Promatch Underbody Wax (PW61)
3M:
Inner Cavity Wax (Transparent) (08909, 08919, 08929)
Inner Cavity Wax (Amber) (08901, 08911, 08921)
Dinol:
Engine Bay & Cosmetic Wax/Lacquer (PW197)
WAX COATINGS Cavity Wax (PW57)
Engine Bay Cosmetic Wax/Lacquer (4010)
Unipart:
Promatch Cavity Wax (UBS508) 
						

							GENERAL SPECIFICATION DATA
3
SEALING AND CORROSION PROTECTION Approved materials (continued)
MATERIAL MANUFACTURER
3M:
Zinc Spray (09113)
WELD-THROUGH PRIMERS ICI:
Zinc Rich Primer (P-565 634)
3M:
Flexible Parts Repair Material (05900)
Cleaner and Wax Remover (1 litre) (08984)
Waterproof Cloth Tape (Y387/YS3998)
GENERAL MATERIALS Teroson:
Sprayable Aerosol, Water Shedder Repair
Unipart:
Waterproof Tape (GWS121)
Urethane Butyl Tape (BHM605) 
						

							04GENERAL SPECIFICATION DATA NEW RANGE ROVER
4
SEALING AND CORROSION PROTECTION MATERIALS APPLICATIONS
Joint Types:
1. Between bolted panels
2. Between bolted panel edges
3. Between spot welded panels
4. Between spot welded panel edges
5. Between bonded panels
6. Between bonded panel edges7. Clinch joints (type a)
8. Clinch joints (type b)
9. Clinch joints (type c)
10. Gaps between panels (type a)
11. Gaps between panels (type b)