Part 1
Body Repairs - General Information - Body Construction
Description and Operation
Introduction
The body plays a significant role in the increasing trend of ever more rapidly changing model variants. The different customer groups are strongly influenced by the design and shape of the body. At the same time the stability of the body plays the most important part in ensuring passenger and driver safety. Lightweight construction, alternative materials, composite materials, plastics and appropriate joining processes are all design features that characterize modern Land Rover vehicle bodies.
In terms of manufacturing technology, modern safety cell bodies can be produced almost without any problems. Land Rover guarantee high quality standards by ensuring that mechanical strength properties are tried and tested in numerous computer simulations, crash tests, by testing materials and by employing sophisticated manufacturing technologies. In the event of repairs it is vital that the production quality standards are upheld. This requires a well-equipped workshop, and places particular emphasis on the qualifications of the workshop technicians. Up-to-date knowledge of current manufacturing technologies and continuous training on new repair methods and techniques are vital for high-quality body repairs. The model-specific repair manuals and the general repair techniques provide valuable support when undertaking body repairs.
Always follow the repair instructions published. Failure to observe this instruction can result in serious impairment of vehicle safety. All specified safety requirements must be met after the work has been carried out.
Contents
This document includes technical data and information for the all new Range Rover L405 aluminum range. The information contained within is valid at the time of production and incorporates:
- Who should use this information?
- Category A and B definition
- Accident damage and diagnosis
- Impact effects on the body
- Planning a repair
- Estimating
- Identifying the correct Land Rover Approved Body Centres
- Obtaining spare parts
- Equipment
- aluminum Information
In line with Land Rover continuous improvement program, information and data contained will be updated periodically.
All activities described within are based on the use of genuine Land Rover Parts, tools and approved materials.
Who should use this information?
The information and repair methods listed are designed as an aid for Land Rover Approved Body Centres achieving the Land Rover approved Bodyshop Operating Standards. The relevant section should be read completely before commencing any repairs. Only technicians who have successfully completed the approved L405 aluminum training program should work on the model. Land Rover Approved Bodyshop Operating Standards require that the skills of technicians be regularly assessed and that any training needs identified are addressed within a reasonable time. This information complements the Land Rover training program.
The authorized repair network is divided into category A and B. The following describes the process required to identify category A or B damage.
Definition of category A and B
Category A (Structural)
NOTE: Specific equipment and facilities are required to carry out Category A repairs, see the equipment section.
Damage that requires panel(s) to be replaced with any one or combination of the following procedures:
- Welded panel
- Bonded panel
- Panel secured with fixings
The following list identifies Category A procedures:
Category A procedures
- Front side member section
- Front side member closing panel section
- Fender apron panel
- Fender apron panel closing panel
- Fender apron panel inner reinforcement
- Suspension top mount
- Front side member and suspension top mount assembly
- Front fender mounting panel
- Front fender supporting panel
- Front fender lower mounting bracket
- Hood latch panel
- Hood latch panel mounting bracket
- Roof panel
- Roof front panel
- Roof rear panel
- Side panel
- Side panel front section
- A-Pillar outer Panel
- A-pillar reinforcement
- Rocker panel
- Rocker panel inner reinforcement
- Rocker panel section
- Rocker panel and B-pillar inner
- B-pillar outer panel
- B-pillar reinforcement
- Quarter panel
- Quarter panel reinforcement
- Inner quarter Panel
- Inner quarter Panel Lower
- Inner quarter panel upper
- Inner quarter Panel Extension
- Rear crossmember
- Rear side member section
- Back panel outer
- Back panel inner
- Rear floor panel section
- Rear floor side extension
- Rear lamp panel inner
- Rear lamp panel outer
- Rear wheelhouse outer
- Water drain panel lower
Category B (Cosmetic)
Damage associated to bolt on panel(s) that are replaced, or light surface damage to exterior cosmetic panels.
The following list identifies Category B procedures:
- Front bumper
- Front bumper cover
- Front bumper lower cover
- Rear bumper
- Rear bumper cover
- Cowl panel grille
- Engine undershield
- Fender
- Fender splash shield
- Hood latch panel
- Front door
- Fuel filler door assembly
- Fuel filler door
- tailgate
Accident damage and diagnosis
General notes:
- Exact diagnosis of the extent of the damage enables proper repair planning
- All body repairs must be carried out in accordance with the guidelines in this Body Repair Manual
- The stability and strength properties of the body must be taken into account during body repairs. The body has exact defined deformation patterns that must not be affected by any repair work
- For instance, the crumple zones absorb the bulk of the impact energy. If any unprofessional repair techniques or methods are used in these areas then this can pose a fundamental threat to vehicle safety
Hidden damage:
- As well as looking at external indicators like flaked off paint, it is vital to check for hidden body damage or deformation that is not visible from the outside. Large attached parts like bumpers and inner fenders often need to be removed to allow accurate assessment of damage to underlying body parts
- Gap dimensions offer another alternative for diagnosis by visual inspection. If any changes or misaligned edges are apparent, then this usually indicates that the dimensions of the affected part are incorrect
Impact effects on the body
It is possible to deduce the overall extent of damage from the direction and magnitude of the impact forces. This does however require extensive body-specific knowledge.
If, for instance, an impact occurs at the front left-hand side member, then the right-hand side member is usually also affected as a result of the rigid body-shell design (crossmember). Often the length of this side member will not have changed, but because of the rigid body-shell design it may have moved from its original position (often only by a very small amount). If any deviations are present this can usually be detected by checking the gap dimensions between door and fender or by checking for changes in dimension.
In the case of more severe impacts, the front part of the body cannot absorb all of the impact energy, and the passenger cell is also deformed. Here the impact energy is transferred via the side member to the A-pillar. This results in deformations in the area of the roof and the door rocker panel.
Planning a repair
The following decisions have to be made before the repairs are started
- Does the vehicle need to be put on a body repair jig?
- Does the body need to be measured?
- Do aggregates like engine or axles need to be removed?
- Which body parts need to be renewed?
- Which body parts can be repaired?
Estimating
The authorized repair network is divided into category A and B. This section describes the process required to identify category A or B damage. Should damage be identified as category A, the vehicle should be referred to the nearest category A facility.
In line with the Land Rover continuous improvement program, information and data contained in this manual will be updated through Land Rover technical bulletins.
The estimating process
STEP 1:
Visual inspection, assess overall vehicle condition. Has damage travelled, distorting internal structural panels?
This is a visual check of the complete vehicle.
Possible indicators:
- Panel misalignment
- Panel gaps no longer uniform
- Hinged panels catch on locks
- Exterior cosmetic panels show signs of stress distortion
- Customer describes unusual driving characteristics post incident
If structural distortion is visible, vehicle body alignment should be checked/corrected on a body repair jig, refer to category A facility.
If no visual indications of damage transfer, go to Step 2.
STEP 2:
If no visual signs indicate distortion to internal structural panels, but the customer is concerned with unusual driving characteristics post incident, and there is no damage to the suspension. Vehicle body alignment should be checked using four-wheel alignment geometry equipment.
If structural distortion is identified refer to category A facility.
STEP 3:
If there is no sign or concern regarding vehicle body alignment, focus on the local area of damage.
Do any of the panels require replacement?
If no, go to Step 4.
If yes, are any of the panels secured with:
- Bonding adhesive?
- Fixings?
- Weld?
If yes, refer to category A facility.
STEP 4:
Do any of the panels require welding i.e. ripped or torn aluminum panel?
If no, go to Step 5.
If yes, refer to category A facility.
STEP 5:
Can the damage be repaired by hand using serrated spoon, dolly, file and/or hot air?
If no, refer to category A facility.
Identifying the correct Land Rover Approved Body Centres
Through extensive research, Land Rover has identified the most appropriate method to rectify aftermarket damage. It is key to safety and vehicle integrity that only the approved methods, materials and equipment are used.
Issues that could arise from the use of non-approved methods, materials and equipment include:
- Warranty invalidation
- Safety
- Galvanic corrosion
Therefore, category A damage should always be referred to a category A Land Rover Approved Body Centres.
Obtaining spare parts
The availability of spare parts often determines how easily the body repairs can be carried out. The following procedure is recommended:
- Obtain all the data for the vehicle, including type, vehicle identification number, trim code, engine identification letters, initial registration etc.
- Establish all of the metal parts that need to be renewed
- Establish all of the attached parts that need to be renewed, including small parts like rivets, clips etc.
Equipment
Land Rover Approved Body Centres are expected to be equipped in line with the Body Centre Tools and Equipment standards.
The approved body equipment for the all new L405 aluminum range is listed as either:
- Category A
- Category B
Body centre approved equipment is also available to order on a global basis from SPX Service Solutions:
A copy of the approved equipment standards for category 'A' and 'B' repair facilities is available on request from and the Global Body Centre Standards have been published on the HUB, along with the personal protective equipment requirements, at the following locations:
https://jaguarhub.hub.tagworldwide.com/index.cfm?brand=42701
https://landroverhub.hub.tagworldwide.com/index.cfm?brand=42701
aluminum Information
The design of the modern motor vehicle attempts to overcome two conflicting needs:
- Fuel economy - lighter, aerodynamic and fuel sensitive technology
- High levels of comfort - this often equates to higher specifications and more accessories
aluminum alloy is the ideal material to meet these demands; it provides a lighter vehicle body with improved rigidity. aluminum is different from traditional Steel, with the correct knowledge and suitable tools it is easily repaired.
There are two aluminum alloys discussed, the attributes detailed in the following table should be considered when deciding to repair or replace:
Other materials are used in the construction of the all new L405 aluminum range, however, repair of these materials is not covered as they fall outside the scope.
Steel, (including Bake Hardened (BH) and High Strength Low Alloy (HSLA): Used in seat belt anchorages, hinge reinforcements and various small brackets and mountings.
Magnesium Die Cast Alloy (AM60B): Used in the hood latch panel.
Plastics: Used in the front fender support bracket and for reinforcements in the B-pillar and rear side member.
The following illustrations identify the aluminum alloys and other materials used in body construction.
Bodyshell
Body closures - front door
Body closures - rear door
Roof panels
Roof panels (moonroof)
Front end panels
Side panels
Rear end panels
Floor panels - rear
Floor panels - center
General Information
Contents
This document includes technical data and information for the all new Range Rover L405 aluminum range. The information contained within is valid at the time of production and incorporates:
- Panel replacement times
- Fixings
- Bonding
- Materials
- aluminum Welding
- Tolerances and gap specification
- Body alignment
In line with Land Rover continuous improvement program, information and data contained will be updated periodically.
All activities described within are based on the use of genuine Land Rover Parts, tools and approved materials.
Panel replacement times
Panel replacement times are available for the following:
- Front end sheet metal repairs
- Roof sheet metal repairs
- Side panel sheet metal repairs
- Rear end sheet metal repairs
Fixings
There are four groups of fixings used on the all new L405 aluminum range, other than conventional nuts and bolts. It is important that the correct procedures are followed for the removal and replacement of these fixings and, where applicable, the correct tools are used.
- Self-Piercing Rivet (SPR)
- Breakstem Fastener
- Countersunk Breakstem Fastener
- Torx Screw and Rivnut
Self-Piercing Rivet (SPR)
CAUTION: Operating the SPR installation tool with no SPR or material in position will damage the tool die.
Self-Piercing Rivets are available in various sizes dependent on the size of the stack of panels to which they are fitted. A stack refers to the combined gauge of the panels being riveted. The following table identifies the sizes and part numbers available:
NOTE: It is important to identify and select the correct size fixing by referencing this table prior to installation.
The two dies referred to in this table are: "Pip die" - Jaguar/Land Rover SPR repair kit, SPX/Avdel part number 78230-050088.
"Flat Bottom die"- Jaguar/Land Rover SPR repair kit, SPX/Avdel part number 78230-050809.
