Body repair (Range Rover 3)

General remarks

Unlike the previous Range Rovers, which had a body bolted to a supporting frame, the new Range Rovers have a monocoque body. The new monocoque body structure significantly increases the body's torsional and bending rigidity. The front, sides and rear of the body have programmable deformation zones. This means that they are able to absorb impact energy, thereby reducing the risk of injury to the driver and passengers of the car.

During body repair, it is necessary to restore the geometric dimensions and strength of the body. During restoration repair, neither a decrease in the strength of the body nor the strengthening of its individual parts is allowed.

The technology of body repair involves either extraction or replacement of individual panels. The repair technology selected in each specific case depends on the ratio of the cost of work and new body panels, as well as the availability of equipment and qualified specialists. The following factors also influence the decision: waiting time for repair, availability of a replacement car and time of repair.

The engineer's task is to select the optimal technology and evenly load the production capacities. The instructions provided in this Manual introduce the body repair specialist to the recommended technology for replacing body panels. The main goal of the recommendations we have developed is to bring the quality of repair work closer to the quality of a new car. A body restored after repair should not be conspicuous even to an experienced expert, although the repair technology may differ from the factory technology. The equipment used for body repair differs from the equipment used during body manufacturing at the factory.



When describing the work in this Manual, the stage of checking the car after the completion of the actual repair and restoration operations is omitted. In this case, it is still necessary to check the work performed, as well as check the wheel alignment angles. If necessary, a road test of the car should be carried out, especially if repairs were made to systems affecting traffic safety.

If the main units of the car were removed during the repair, then after their reinstallation do not forget to check the oil or special fluid level. If necessary, add oil (special liquid). It is also necessary to make sure that the external lighting devices are in good working order, check the air pressure in the tires, the presence of fluid in the windshield washer reservoir, as well as the condition of other systems, the failure of which prohibits the operation of the car.

Carrying out body repairs often requires removing various mechanisms or components of electrical equipment and wiring. For proper removal and installation of components, refer to the instructions in the relevant sections of this Manual.

Despite the variety of body types, suspensions, engines and transmissions, it is necessary to ensure the correct location of the attachment points of the following components:

• Upper mounting points of the front suspension shock absorber struts.
• Subframe mounting points and additional front suspension mounting points.
• Engine mounting points.
• Upper mounting points for rear suspension shock absorbers.
• Lower rear suspension arm mounting points.

To check the geometry of the body, you can use additional base points:

• Holes in the crossbars connecting the side panels to the front floor panel.
• Holes in the radiator frame.
• Holes in the rear side members.
• Holes in the lower panels of the rear of the car.

The size of the windshield openings, rear door glass, bonnet and doors should be measured and compared with the given values, you can also take the size of the new element as a sample.

Straightening and stretching

The elements of the body frame should, if possible, be straightened in a cold state under the action of static force. Do not straighten the panels in one go, straighten them in several steps, check the geometry of the body after each stage and completely release the acting forces.

Securing the body

In all cases, except for straightening the trim panels, the body should be installed on a special stand. This will allow you to assess the true extent of the damage. In addition, when installing the body on the stand, the possibility of body deformations during stretching or replacing panels will be excluded.

If it is not possible to restore the geometric dimensions of the body by stretching the body, then the damaged panels must be replaced. Damaged panels should be cut out using a cutting wheel; it is PROHIBITED to use oxygen-acetylene cutters for these purposes.

As a rule, the dimensions of the body are symmetrical relative to the longitudinal axis of the car. For the initial check of the body deformation, it is recommended to measure the dimensions of the diagonals and determine their difference.

Inspection of the body after impact

Each collision results in deformation of body elements. Each time, deformation occurs differently. The technology of restoration repair depends on the nature of the damage received and the available equipment.

In most cases, the damage can be visually determined. But sometimes there is deformation of body sections that are remote from the impact site.

In such cases, the geometry of the body should be carefully checked for subsequent restoration to the values specified in the drawings. The initial check can be carried out using meters or calipers. (the use of the latter is preferable).

The use of special equipment for straightening damaged bodies allows for precise measurement of the geometric dimensions of the body and their deformation as a result of torsion.

[The full version is available on the website LRMAN.RU]