Range Rover : Body Repairs

Range Rover : Body Repairs

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The Range Rover body consists of a steel frame to which alloy outer panels are attached. The cowl panel, front fenders, side door outer panels, body side outer panels and roof are made from a special light magnesium-aluminium alloy. The manufacture of body panels from aluminium has two distinct advantages, the first of which is a much better resistance to corrosion, the second being a decrease in the gross vehicle weight. Aluminium panels can be effectively repaired using the `Argon Arc ' process of welding, because the afore mentioned is a specialist operation it is necessary that only a skilled operator or specialist body shop undertake such repairs. .: Under certain conditions it may' not be practical to repair an exterior damaged panel, if this is the case, then panels can be easily removed and replaced with new ones (refer to the appropriate part of the Body section for panel removal and refit). Panel beating 1. Aluminium alloy panels can be beaten out after accidental damage in the same way as sheet steel. However, under protracted hammering the material will harden, and then it must be annealed to prevent the possibility of cracking. This is quite easily done by the followed by slow application of heat, air-cooling, but as the melting point is low, heat must be applied slowly and carefully.

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 1 9 8 7
C H A S S I S A N D B O D Y
BODY REPAIRS, GENERAL INFORMATION W e l d i n g The Range Rover body consists of a steel frame to CAUTION: T h e b a t t e r y g r o u n d l e a d M U S T b e which alloy outer panels are attached. The cowl d i s c o n n e c t e d b e f o r e c o m m e n c i n g w e l d i n g . I F panel, front fenders, side door outer panels, body WELDING IS TO BE CARRIED OUT ON THE REAR side outer panels and roof are made from a special RIGHT HAND FENDER, THE FENDER MUST BE light magnesium-aluminium alloy. REMOVED, AS A FUEL EXPANSION TANK IS LOCATED BETWEEN THE FENDER AND INNER The manufacture of body panels from aluminium BODY SIDE. has two distinct advantages, the first of which is a much better resistance to corrosion, the second 1. Clean off all grease and paint, dry thoroughly being a decrease in the gross vehicle weight. and then clean the edges to be welded, and an area at least half an inch on either side of Aluminium panels can be effectively repaired using the weld, with a stiff wire scratch brush or the ‘Argon Arc process of welding, because the wire wool. Cleanliness is essential. Also clean  m e n t i o n e d i s a s p e c i a l i s t o p e r a t i o n i t i s the welding rod or strip with steel wool. necessary that only a skilled operator or specialist 2. It is strongly recommended that a few welds body shop undertake such repairs. are made on scrap metal before the actual repair is undertaken if the operator is not Under certain conditions it may’ not be practical to already experienced in welding aluminium and repair an exterior damaged panel, if this is the case, its alloys. then panels can be easily removed and replaced 3. Use only 5 per cent magnesium aluminium with new ones (refer to the appropriate part of the welding rod (5 Body section for panel removal and refit). Welding tears and patching Panel beating 1. If a tear extends to the edge of a panel, start 1. Aluminium alloy panels can be beaten out the weld from the end away from the edge after accidental damage in the same way as and also at this point drill a small hole to sheet s t e e l . H o w e v e r , u n d e r p r o t r a c t e d p r e v e n t t h e c r a c k s p r e a d i n g , t h e n w o r k hammering the material will harden, and then towards the edge. it must be annealed to prevent the possibility 2. When welding a long tear, or making a long of cracking. This is quite easily done by the welded joint, tack the edges to be welded at application o f h e a t , f o l l o w e d b y s l o w intervals of from 2 in to 4 in (50 air-cooling, but as the melting point is low, with spots. This is done by melting the metal heat must be applied slowly and carefully. at the starting end and fusing into it a small amount of the filler rod, repeating the process CAUTION: B e f o r e a p p l y i n g h e a t t o a n y p a n e l at the suggested intervals. After this, weld e n s u r e t h a t t h e p a n e l i s c l e a n a n d f r e e f r o m continuously along the joint from right to left, underseal and that the area to be worked on is i n c r e a s i n g t h e s p e e d o f t h e w e l d a s t h e well clear of any combustible materials. Ensure material heats up. that all necessary precautions are taken against 3. When patching, cut the patch to the correct fire. IF HEAT IS TO BE APPLIED TO THE REAR shape for the hole to be filled, but of such RIGHT HAND FENDER, THE FENDER MUST FIRST sizes as to leave a gap of in BE REMOVED AS A FUEL EXPANSION TANK IS between it and the panel, and then weld as LOCATED BETWEEN THE FENDER AND INNER described above. Never apply an ‘overlay’ BODY SIDE. patch.
1
 ‘CHASSIS AND BODY
Spot welding . 1. spot welding is mainly used in the manufacture of the Range-Rover inner steel body frame and exterior magnesium-aluminium alloy panels, and is a process which can be carried out satisfactorily by the use of the proper apparatus in a specialist body shop. Aluminium and its alloys are very good conductors of heat and electricity, and thus it is most important to maintain the right conditions for successful spot welding. The correct current density must be maintained, and so must the ‘dwell’ of the electrodes.  Special spot welding machines have been developed, but they are expensive, and though the actual work can be carried out by comparatively unskilled supervision and machine maintenance must be in the hands of properly qualified persons. Riveting 1. Where both sides of the metal are accessible and it is possible to use an anvil or ‘dolly’ solid aluminium rivets may be used, with a suitable punch or ‘pop’ to ensure clean rounded head on the work. For riveting blind holes, pop-rivets’ must be used. These are inserted and closed by special ‘pop-rivet’ pliers.
2
1987 ROVER
PAINTWORK General Information Before undertaking any paintwork process on the exterior body of Range Rover, firstly ascertain which is the best method of repair either by panel repair or replacement. The initial preparation of a panel is very important to ensure that when finished it is of a standard that meets and matches existing bodywork. Panels must be thoroughly degreased with Berger Preclean 802.0516 or a suitable equivalent, any unsound paint to be stripped using Berger Double strength  3 0 1 . 8 0 5 1 . A l w a y s r e f e r t o t h e p a i n t manufacturers instructions. Paintwork processes should be performed by a specialist where paint spraying can be undertaken in a controlled environment whereby temperatures are kept constant and the atmosphere dust free. The flow chart on the following page gives a guide to preparing and painting a panel. Wherever possible refer to the Berger Vehicle Refinishes Product Data and Application Sheets for further information.
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R O V E R  1987
S U B S T R A T E
P A N E L R E P A I R
‘ R E P A R A T I O N Vet for using Grade paper or dry and using grit discs.
 F I L L I N G f filling is required, thoroughly  bare area to be  and apply Polyester  
itch the bare aluminium and fille  auto-speed self etch  414-1171, mixed with  Apply one coat and  to dry for approximately 20 ninutes.  within hour.
‘ R I M I N G
COLOUR COATING
CHASSIS AND BODY
 P A N E L S R E P L A C E M E N T P A N E L
Wet flat usin Grade paper or dry sand using grit discs. Care must be taken to cutting through to bare aluminium.
If filling is required, fill small indentations with Polyster stopper
This process is not required if the original electrocoat primer is in
To obtain maximum adhesion and excellent build, appl 2K full primer Coats of 30-40 microns can be wet flatted with grade paper after 45 minutes at 20°C.
Apply either 2K Standocryl or Metallic Basislack to the required. Hardeners and will depending upon system employed, conditions available, temperature and size of vehicle etc. Refer to paint manufacturers Technical Information Sheet for correct selection.
 
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 1987-90 CHASSIS FRAME Alignment check Diagram reference AA Wheelbase-Reference dimension BB Centre line of front axle c c Centre line of rear axle D D Frame datum line EE Side member datum line FF Datum line (with mounting washers) (without washers) 2 3 4 5 6 7 8 9 10 11 12 13A 14 Reference dimension 15 To face of boss 16 Frame datum to underside of cross-member 17 18 19 Check figure 20 21 22 23 24 25 26 27 28 29 30 31
C o n t i n u e d
CHASSIS AND BODY
m i l l i m e t r e s 2540.00
254.00 0.63 263.525 + 1.91 0.63 261.11 2.54 266.70 2.54 237.74 1.27 327.81 2.54 979.93 1.27 2244.72 2.54 356.74 2.54 605.15 2.54 1405.38 2.54 694.44 2.54 338.83 2.54 222.25 5.08 240.54 2.54 794.91 935.43 2.54 150.79 535.94 2.54 590.55 0.64 630.93 344.17 1.27 485.77 2.54 485.77 2.54 414.32 2.54 129.03 2.54 2544.44 0.25 1355.34 0.38 1722.04 0.38 2663.44 0.38 144.09 0.38 400.48 2.54 1333.88 0.38
inches 100.000
10.000  10.375 +  10.180  10.500   12.906  38.580 88.375  14.045 23.825 55.330 27.340 13.340 8.750 9.470 31.296 36.828 5.937 21.100 23.250 24.840 13.550 19.125  19.125  16.312 5.080 100.175 53.360 67.797 104.860 5.673 15.767 52.515 
5
 .
CHASSIS AND BODY
32 Reference dimension 3 3 Reference dimension 3 4 Reference dimension SECTION XX 35 Frame datum line DD 3 6 3 7 S E C T I O N 3 8 Frame datum line DD 39 40
S E C T I O N Z Z 4 1 Frame datum line DD 42 43 44
m i l l i m e t r e s 925.49 147.62 635.00
488.95 2.54 295.27 2.54
660.40 0.17 MO.95 + 1.91 0.63
80.95 + 1.91 0.63 660.4 0.17 9.525 2.54
RANGE  inches 36.437 . 5 . 8 1 2 25.000
19.250  11.625 
26.000 3.187 +
3.187 + 26.000 0.375
CHASSIS AND BODY  
BODY Spot welding is satisfactory if the joints do not pull apart. If the weld pulls a hole or tears the metal the Introduction: weld is satisfactory. It is defective if the weld joint pulls apart or if there are signs of burning, porosity The information which follows is concerned solely or cracking evident. with the ‘Monocoque’ assembly of the inner body shell on Range Rover models. P R E P A R A T I O N Body repairs often r e q u i r e t h e r e m o v a l o f Thoroughly clean all areas to be welded, remove mechanical and electrical units and associated any sealants and corrosion protectives from around  wiring. Where necessary, reference should be made original panels. Align and clamp all new panels in to the relevant section of the Repair Manual for position and check relationship to one another. removal and refitting instructions. Continued The inner body shell is of ‘Monocoque’ construction and to gain access to the repair area, it may be necessary to remove exterior body panels, all exterior body panels are bolted to the inner body shell to facilitate easier panel removal and replacement or repair. 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 i n t e n d e d t o a s s i s t a s k i l l e d b o d y r e p a i r e r b y expanding approved procedures for panel replacement with the objective of restoring the car to a safe running condition and effecting a repair which is visually acceptable. W E L D I N G T h e f o l l o w i n g c h a r t s a n d i l l u s t r a t i o n s s h o w t h e locations and types of weld for securing the body side assembly, tailgate frame assembly and the front valance and wheel arch assembly. Before undertaking any spot weld joints to the inner body, it is advisable to make a test joint usin of  the damaged components, and to use this test piece to perform a weld integrity test.
 CHASSIS AND BODY
INNER BODY SHELL ASSEMBLY
A. B. C.
LOCATION Front cross to valance and wheel arch assembly Hood locking platform to valance and wheel arch assembly Valance and wheel arch assembly to dash and tunnel assembly Body side complete to dash and tunnel assembly
1987-90 RANGE
FA CTO R Y JOINT (minimum number of spot welds quoted) 6 spot welds, 20mm pitch
10 spot welds, 25mm pitch
16 spot welds, 25mm pitch
 spot welds, 65mm pitch
       
  987-90
LOCATION E LOCATION E. 1. Body side complete to heelboard panel assembly. 2. Body side complete to dash and tunnel assembly complete. 3. Body side complete to dash and tunnel assembly I . Body side complete to dash and tunnel assembly complete 2. Body side complete to dash and tunnel assembly complete 3. Body side complete to dash and tunnel assembly complete
CHASSIS
LOCATION F FACTORY JOINT (minimum number of spot welds quoted)  spot welds, pitch 10 spot welds, 25mm pitch 3 spot welds, 30mm pitch 7 spot welds, pitch  spot welds, 40mm pitch 30 spot welds, 34mm pitch
Continued
 
 
9
 CHASSIS AND BODY
LOCATION LOCATION G. Reinforcement plate to dash and tunnel assembly and body side assembly complete H. 1. Body side complete to roof header panel assembly (internal joint) 2. Body side complete to roof header panel assembly (internal joint)
LOCATION H FACTORY JOINT (minimum weld requirement quoted) CO, weld, 2 places 75mm long each weld
3 spot welds, 15mm pitch 3 spot welds, pitch
1987-90 RANGE
I.
K.
LOCATION
LOCATION
1. Body side complete to rear tailgate frame assembly
1. Body side complete to roof header panel assembly (external joint) 2. Body side complete to roof header panel assembly (external joint)
LOCATION K
FACTORY JOINT (minimum weld requirement quoted)
Continued
weld, one run 40mm long
weld, one run 20mm long
weld, one run
long