Body Repairs: General
Unlike previous Range Rovers that had a body shell bolted to a chassis frame, the new Range Rover has a steel monocoque body. This monocoque construction gives significant improvements in torsional rigidity and bending stiffness. Front, side 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 minimize 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 repair.
Repairs usually involve a combination of operations ranging from straightening procedures to renewal of individual panels or panel assemblies. The repairer will determine the repair method and this decision will take into account a balance of economics between labor and material costs and the availability of repair facilities in both equipment and skills. It may also involve considerations of the vehicles' downtime, 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. The objective is to restore the vehicle to a safe running condition by carrying out a repair which is as close as is feasible to original standard. The results should not advertise to the experienced eye that the vehicle has been damaged, although the repair might not be identical in all respects to the original factory build. Commercial bodyshop repair facilities cannot always duplicate methods of construction used during production.
Operations covered in this article do not include reference to testing the vehicle after repair. It is essential that work is inspected and suspension geometry checked after completion. Where necessary a road test of the vehicle should be 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 where necessary. It is also necessary to ensure that the repaired vehicle is in a roadworthy condition in respect of tire pressures, lights, washer fluid etc.
Body repairs often involve the removal of mechanical and electrical units and associated wiring. Where necessary, refer to the relevant article for removal and refitting instructions.
Taking into consideration the differences in body styles, suspension systems, engine and transmission layouts, the location of the following components as applicable to a particular vehicle is critical:
- Front suspension upper damper mountings.
- Sub frame mountings and additional front suspension mounting points.
- Engine mountings.
- Rear suspension upper damper mountings.
- Rear suspension mountings or lower pivots.
Additional points which can be used to check alignment and assembly are:
- Inner holes in cross member - side - main floor.
- Holes in front bulkhead.
- Rear longitudinal tooling and fixing holes.
- Holes in rear lower panels.
Apertures for windscreen, rear screen, bonnet and doors can be measured and checked using the dimensional information provided and also by offering up an undamaged component as a gauge.