Land Rover Range Rover Body Repair Rover Manual

							GENERAL SPECIFICATION DATA
5
SEALING AND CORROSION PROTECTION Materials applications (continued)
MANUFACTURER MATERIAL/JOINT TYPE
ICI P565 634 Zinc rich primer. Between bolted and spot welded panels,
3M 09113 clinch joints (type a). Brush or spray application.
Teroson Terostat V11 Preformed strip. Between bolted panels. Hand application.
Kent Industries 10075
3M 08401
3M 08572
3M 08684
3M 08689
3M 08694
3M 08703 Seam sealer. Between bolted panel edges. Applicator gun/by hand.
3M 08783
3M 08788
PPG Polyurethane 6500
Teroson 92
Terolan Light
Terostat 1K PU
Terostat 9320
Unipart UBS 605/6/7
Wurth 890100/1/2/3/4/5/6
Ciba-Geigy XBS106/7 Structural adhesive. Between spot welded and bonded panels,
3M 08120 clinch joints (type a). Applicator gun, caulking gun.
3M 08625 Seam sealer. Between spot welded panels. Applicator gun.
Kent Industries 10075
3M 08401
3M 08684
PPG 6500
Teroson 92 Seam sealer light. Between spot welded panel edges.
Terolan Light Hand applicator gun.
Terostat 9320
Terostat 1K PU
Unipart UBS605/6/7
Wurth 890100/1/2/3/4/5/6 
						

							04GENERAL SPECIFICATION DATA NEW RANGE ROVER
6
SEALING AND CORROSION PROTECTION Materials applications (continued)
MANUFACTURER MATERIAL/JOINT TYPE
Ciba-Geigy XBS106/7 Structural adhesive. Between bonded panels. Caulking gun.
3M 08120
PPG 6500
Teroson 92
Terostat 9320 Semi-structural adhesive/anti-flutter material. Between
Unipart UBS605/6/7 bonded panels. Caulking gun.
Wurth 890100/1/2/3/4/5/6
Kent Industries 10075
3M 08401
3M 08694
PPG 6500 Seam sealer light. Between bonded panel edges.
Teroson 92 Hand applicator gun.
Teroson Light
Teroson 9320
Terostat 1K PU
Unipart UBS605/6/7
Wurth 890100/1/2/3/4/5/6
Gurit-Essex 10211
Gurit-Essex 10215
Gurit-Essex 10220
3M 08531 Seam sealer. Clinch joints (type b). Caulking gun.
3M 08537
3M 08703
3M 08783
3M 08788 
						

							GENERAL SPECIFICATION DATA
7
SEALING AND CORROSION PROTECTION Materials applications (continued)
MANUFACTURER MATERIAL/JOINT TYPE
Kent Industries 10075
3M 08401 Seam sealer light. Clinch joints (type c). Caulking gun,
3M 08531 hand applicator gun.
Teroson Terolan Light
Kent Industries 10075
3M 08401
3M 08684
3M 08689
3M 08694 Seam sealer light. Gaps between panels (type a).
PPG 6500 Hand applicator gun.
Teroson 92
Terolan Light
Terostat 1K PU
Unipart UBS605/6/7
Wurth 890100/1/2/3/4/5/6
Kent Industries 10075
Kent Industries Putty
3M 08401
3M 08531
3M 08568
3M 08684
3M 08689 Seam sealer heavy. Gaps between panels (type b). Hand
3M 08694 applicator gun, applicator tube or caulking gun.
PPG 6500
Teroson 92
Terolan Light
Terostat 9320
Terostat 1K PU
Unipart UBS605/6/7
Wurth 890100/1/2/3/4/5/6
Gurit-Essex 10101
Gurit-Essex 10707
3M 08537
Gurit-Essex 10211
Gurit-Essex 10215 Brushable sealer. Overlap joints (e.g. floor pans).
Gurit-Essex 10220 Brush.
Teroson Brushable Sealer
Croda PW57
3M Cavity Waxes Cavity wax. Box members, sills. Injection equipment.
Unipart UBS508 
						

							04GENERAL SPECIFICATION DATA NEW RANGE ROVER
8
SEALING AND CORROSION PROTECTION Materials applications (continued)
MANUFACTURER MATERIAL/JOINT TYPE
Croda PV75
3M 08861
3M 08877 Underbody sealing coat. Underbody. Schutz gun, aerosol.
Teroson Terotex Underseal
Unipart UBS410
Croda PW61
Dinol 205 Underbody wax coat. Underbody. Spray gun or brush.
Unipart PW61
Astors 3241/3
Croda PW197 Engine bay cosmetic wax/lacquer. Spray gun or brush.
Dinol 4010
3M Stone Chip Anti-chip coating. Sill panels. Schutz gun.
Coatings
3M 05900 Plastic Two-pack material. Repair of plastic parts.
Parts Repair Material Spreader or palette knife.
3M 08509 Dry glazed windscreen sealer. Applicator gun.
Unipart BHM605 Urethane butyl sealer for direct glazing. Caulking gun.
3M YS3998
3M Y387 Waterproof tape for sealing apertures. Hand application.
Unipart GS121
Evode Evo-Stik
3M 08030
3M 08034 Trim fixing adhesive. Brush or aerosol.
3M 08080
3M 08090
3M 08984 Adhesive cleaner/wax remover. Hand application with cloth. 
						

							GENERAL SPECIFICATION DATA
9
SEALING AND CORROSION PROTECTION APPLICATION EQUIPMENT
SATA Schutz Gun Model UBE
Specifications:
Air consumption 200 litres/min. (7cu/ft. min.) @ 45PSI...............................................................
Weight 660grams (23.3oz)..............................................................................
Manufactured and supplied by:
Sata Gmbh
Minden Industrial Ltd.
16 Greyfriars Road
Moreton Hall
Bury St. Edmunds
Suffolk IP32 7DX
Tel. (01284) 760791
The Sata Schutz Gun is approved for the re-treatment
of vehicle underbody areas with protective coatings as
supplied in 1-litre (1.76pt.), purpose-designed,
one-way containers. The screw thread fitting (female
on the gun) will fit most Schutz-type packs.
Full operating details are supplied with the equipment.
NOTE: Always clean gun after use with the
appropriate solvent.
Sata HKD1 Wax Injection Equipment
The Sata HKD1 is approved by Rover for use in all
cavity wax re-treatment operations. The equipment
comprises a high quality forged gun with 1-litre
capacity pressure feed container, a flexible nylon
lance, 1100mm (43.3in.) straight steel lance and
hooked wand lance. A quick-change coupling is a
standard fitting to enable lances to be easily
interchanged. The lances each have their own spray
pattern characteristics to suit the type of box section
to be treated.
The Sata HKD1 is covered by a 12 month warranty.
All replacement parts and service are obtainable from
the suppliers. 
						

							04GENERAL SPECIFICATION DATA NEW RANGE ROVER
10
SEALING AND CORROSION PROTECTION Cooper Pegler Falcon Junior Pneumatic (Airless)
Manufacturer and supplier:
Cooper Pegler & Co. Ltd.
Burgess Hill
Sussex RH15 9LA
Tel. 04 446 42526
Intended primarily for applying transit wax, the Falcon
Junior pneumatic sprayer has a 5-litre (1 gal.)
container with integral hand pump. This high quality
unit provides a simple and effective means of wax
spraying without the need for compressed air or
additional services.
A selection of nozzles, lances and hoses together with
a trigger valve assembly incorporating a filter enable
the sprayer to be used in a variety of applications.
These include general maintenance, wax injection and
paint application. All parts are fully replaceable and
include a wide range of nozzle configurations.
The Falcon Junior is fitted with Viton seals and is
guaranteed for 12 months.3M Application Equipment
Manufacturer:
3M UK PLC
Automotive Trades Group
3M House
PO Box 1
Market Place
Bracknell
Berks. RG12 1JU
Tel. (01344) 858611
All 3M equipment is available from local trade factors
or 3M refinishing factors.
3M Caulking Gun 08002
A lightweight, robust metal skeleton gun designed to
accommodate 325mm (12.8in.) cartridge for
dispensing sealants etc. This gun facilitates rapid
cartridge loading and features a quick-release lever
for accurate material ejection and cut-off control.
3M Pneumatic Cartridge Gun 08012
An air line fed gun for application of 3M cartridge
products. Excellent ease of application for a smooth
sealant bead, and incorporates a regulator valve for
additional control.
Other 3m applicator equipment available:
3M Pneumatic Applicator Guns
Air line fed gun for application of 3M sachet sealers
(Part No. 08006 for 200ml [6fl/oz.] and 310ml [9fl/oz.]
sachets, and Part No. 08007 for all size sachets
including 600ml [18fl/oz.]).
3M Applicator Gun 08190
For application of 3M Structural Adhesive 08120.
3M Inner Cavity Wax Applicator Gun
Features 750mm (29.6in.) flexible tube and using
1-litre (1.76pt.) canisters, this approved equipment is
available from all 3M refinishing factors.
Other 3m applicator equipment available:
Heavy Duty Manual Gun. 
						

							GENERAL SPECIFICATION DATA
11
SEALING AND CORROSION PROTECTION MATERIALS GUIDE
3M Automotive Structural Adhesive 08120
a two-part epoxy structural adhesive, with automix
twin-cartridge dispenser. For doorskin and for bonding
panel stiffeners. Supplied as twin pack for use in small
trigger gun (No. 08190).
3M Bolted Panel Sealer 08572
Preformed strip 20mm (0.8in.) wide x 2mm (0.08in.)
thick supplied in 4.6 metre (81.2in.) reels.
Permanently flexible with good adhesion, for sealing
wing to body joints and other bolted or riveted panels.
3M Body Caulking 08568
Thumb-applied sealing compound supplied in
60-packs of preformed strips 300mm (11.8in.) long x
6mm (0.24in.) wide. For sealing large openings and
fissures. Non-hardening, does not dry out or crack,
can be overpainted immediately.
3M Drip-Chek Sealer Heavy 08531
For use on vertical fissures and seams up to 3mm
(0.12in.) wide for a firm but flexible seal which will not
harden or shrink. Self-levelling, will not sag on vertical
surfaces. May be worked with a tool or smoothed with
a wet finger.
Supplied in 150ml (4.5fl/oz.) tubes.
3M Drip-Chek Sealer Clear 08401
An easily flowing sealer similar to Drip-Chek Heavy
but of clear consistency. Ideal for an almost invisible
spot weal over finished paintwork. Can be overpainted
or even mixed with paint colour to form a self-coloured
sealant.
Supplied in 150ml (4.5fl/oz.) tubes.3M Super Seam Sealer 08537
A brushable sealer designed to simulate original
factory-applied sealer on all overlap joints such as
floor pans, wheel arches, boot and load space seams
and fuel filler cap surrounds. Resistant to oil, petrol
and water. Should be brushed on inONEdirection
only for best results.
WARNING: Must be stored under
conditions applicable to highly flammable
materials.
3M Flexseal 08684, 08689 AND 08694
A high solid, non-shrinking, polyurethane body sealer
for use in either a hand gun or pneumatic applicator
gun. Excellent adhesion and sealing properties.
Resistant to oil, petrol and water. Supplied in 310ml
(9fl/oz.) cartridges and in a choice of black, white or
grey.
3M Polyurethane Sachet Sealer 08703, 08783,
08788
Similar to Flexseal polyurethane but available in
collapsible foil sachets in 310ml (9fl/oz.) and 600ml
(18fl/oz.) sizes with a choice of three colours: black,
grey or white.
3M Windscreen Sealer 08509
Non-hardening sealant for dry-glazed,
weatherstrip-type windscreens. Applied with applicator
gun.
Supplied in 310ml (9fl/oz.) cartridges.
3M Spray Schutz 08877, Body Schutz 08861
Flexible, rubberised, fast-drying coating which dries to
a black textured finish.
Spray Schutz supplied in 600ml (18fl/oz.) aerosols.
Spray Schutz and Body Schutz also supplied in 1-litre
(1.76pt.) cartridges to fit Schutz Gun. 
						

							04GENERAL SPECIFICATION DATA NEW RANGE ROVER
12
SEALING AND CORROSION PROTECTION 3M Flexible Parts Repair Material 05900
A fast-curing, two-part system for repairing minor
damage to plastic bumpers, spoilers, valances etc.
Dries in 30 mins.
Supplied as two-pack 320ml (10fl/oz.) kit.
3M Weld Thru SEALER 08625
For anti-corrosion protection between spot welded
panels. Brush application.
Supplied in 1-litre (1.76pt.) canisters.
3M Bodygard
Rubber-based, stone chip protective coating for
panels. Fast drying, low bake compatible and may be
overpainted. Varying textures obtainable depending
on type of finish required. Available in black (1-litre
[1.76pt.] pack 08858, aerosol 08158) or grey (1-litre
[1.76pt.] pack 08859, aerosol 08159).
3M Inner Cavity Wax
For protective coating on inner panels. Excellent
anti-corrosion properties. Available in transparent or
amber consistencies, and 1-litre (1.76pt.) canister or
500ml (0.88pt.) aerosol packs.
3M Zinc Spray 09113
Anti-corrosive coating for spot welding applications on
joints and seams. Supplied in 500ml (0.88pt.) aerosol
packs.
3M Waterproof Cloth Tape YS3998
Black waterproof tape for sealing door apertures and
body box section access holes. Long-lasting,
moisture-resistant adhesive will withstand immersion
in water.
Supplied in 50-metre (164.2ft.) rolls in a variety of
widths.
3M Adhesive Cleaner and Wax Remover 08984
For surface preparation before application of most
types of adhesive, coating and sealant, also for
removal of tar, silicone polish, wax, grease and oil.
Non-staining. May also be used for cleaning adhesive
remnants from sander disc backing pads.
Supplied in 1-litre (1.76pt.) canisters. 
						

							ELECTRONIC AIR SUSPENSION
1
DESCRIPTION AND OPERATION ELECTRONIC AIR SUSPENSION - EAS
Description
The Range Rover concept of air supension is already
well established, the system fitted to the New Range
Rover is broadly similar. Progressive development
has resulted in added features to improve the control
and operation of the system.
Air springs provide a soft and comfortable feel to the
ride of the vehicle. The use of a microprocessor to
control the system exploits the advantages of air
suspension.
The system provides a near constant ride frequency
under all load conditions resulting in:
·Improved ride quality
·Consistency of ride quality
·Constant ride height
·Improved headlamp levelling
The system provides five ride height settings plus self
levelling. Each setting is automatically maintained at
the correct height by the system logic with the
minimum of driver involvement. Vehicle height is
sensed by four rotary potentiometer type height
sensors. Height information from each sensor signals
the electronic control unit (ECU) to adjust each air
spring by switching the solenoid valves to hold, add or
release air.
The five height settings are as follows:
Standard: Profile
Low profile:25 mm (1 in.) below standard.
Access:65 mm (2.6 in.) below standard. Crawl: It is
possible to drive at the access ride height at speeds
less than 32 km/h (20 mph), where headroom is
restricted.
High profile:40 mm (1.6 in.) above standard.
Extended profile:70 mm (2.75 in.) above standard.
This setting is not manually selectable.Self levelling
On a coil sprung vehicle the effect of adding weight is
for the vehicle to lean either from front to back or side
to side unless the increased weight is evenly spread.
With air suspension, the system detects this body lean
and automatically compensates for it. The vehicle will
self level to the lowest corner height for 20 seconds
each time the driver exits vehicle and closes the
doors.
The system will check vehicle height every 6 hours
and make minor corrections, not exceeding 8 mm,
(0.31 in) as necessary.
When unloading through the tailgate the system will
self level to compensate for the decreased load after
door closure.
NOTE: If the vehicle is parked on uneven
ground or with a wheel or wheels on the
kerb, self levelling will lower the vehicle to
the lowest spring height.
CAUTION: The underside of the vehicle
must be kept clear of any obstacles while
the vehicle is parked, as self levelling may
result in a reduced trim height.
WARNING: Before commencing work
which requires access to the underside or
wheel arches of the vehicle, the
suspension must be allowed to relevel.
Relevelling is achieved by opening and closing of
any of the side doors, while all other doors and
tail gate remain closed, and the ignition off.
EAS must be set in high-lock using TestBook,
during any work which does not require chassis
to axle displacement. This will hold the
suspension in extended profile position, until
reset by TestBook. 
						

							60FRONT SUSPENSION NEW RANGE ROVER
2
DESCRIPTION AND OPERATION LOCATION OF COMPONENTS
Key to location of components
1. Electrical control unit
2. Compressor
3. Air dryer
4. Valve block
5. Reservoir
6. Height sensors front7. Height sensors rear
8. Front air spring
9. Rear air spring
10. Relays, fuses
11. Driver controls