Freelander 1. Manual - part 234

BODY DIMENSIONS

BODY GAPS AND PROFILES 77-1-19

The tolerance for sections E-E and F-F is 

±

 1.0 mm (0.040). The other dimensions all have a tolerance of 

±

 0.5 mm 

(0.020).

Section D-D, if the wing has been exposed to oven curing set gap to 4.4 mm (0.173) to enable subsequent expansion.

Section G-G, profile of wing to front door is 0.0 nominal, tolerance  +1.0 (0.040) / -0.0.

Section H-H and J-J, profile of front door frame to body is -2.5 mm (0.098) nominal, tolerance +0.0 / -1.0 mm (0.040).

Section K-K and L-L, profile of front door to rear door is 0.0 nominal, tolerance +0.0 / -1.0 mm (0.040).

Section N-N and P-P, profile of rear door to body is 0.0 nominal, tolerance +1.0 (0.040) / -0.0.

BODY DIMENSIONS

77-1-20 BODY GAPS AND PROFILES

The tolerance for sections P-P and Q-Q is 

±

 0.5 mm (0.020).

Section

Gap

Description

Dimension

P-P

p

Taildoor to rear lamp

5.0 (0.196)

Q-Q

q

Taildoor to rear bumper

6.0 (0.236)

PANEL REPAIRS

BODY REPAIRS

77-2-1

PANEL REPAIRS

General
Body shells are of monocoque construction. Front 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 minimise 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 labour 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 Manual 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 tyre 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 section of the Workshop Manual for removal and refitting instructions.

Body components
Taking into consideration the differences in body styles,  suspension systems and engine and transmission layouts, 
the location of the following components as applicable to a particular vehicle is critical:

l

Front suspension upper damper mountings.

l

Front suspension or sub frame mountings.

l

Rear suspension upper damper mountings.

l

Rear suspension mountings or lower pivots.

Additional points which can be used to check alignment and assembly are:

l

Inner holes in crossmember - side - main floor.

l

Holes in front longitudinals.

l

Holes in side members.

l

Holes in rear longitudinals.

l

Holes in rear lower panels or extension rear floor.

Apertures for windscreen, backlight, bonnet and doors can be measured and checked  using the dimensional 
information provided and  also by offering up an undamaged component as a gauge.

Straightening
Whenever possible, structural members should be cold straightened under tension. Do not attempt to straighten with 
a single pull but rework the damaged area using a series of pulls, releasing tension between each stage and using 
the opportunity to check alignment.

PANEL REPAIRS

77-2-2

BODY REPAIRS

Body jig
Unless damage is limited to cosmetic panels, all repair work to body members must be carried out on a body jig, to 
ensure that impact damage has not spread into more remote parts of the structure. Mounting on a jig will also ensure 
that the straightening and panel replacement procedures do not cause further distortion.

If original dimensions cannot be satisfactorily restored by these methods, damaged structural members should be 
replaced. Damaged areas should be cut away using a high speed saw, NOT an oxy-acetylene torch.

As a rule, body dimensions are symmetrical about the centre line. A good initial check for distortion is therefore to 
measure diagonally and to investigate apparent differences in dimensions.

Inspection
Every accident produces individual variations in damage. Each repair is influenced by the extent of the damage and 
the facilities and equipment available for its rectification.

Most accident damage can be visually inspected and the approximate extent of damage assessed. Sometimes 
deformation will extend beyond the directly damaged area, and the severity of this must be accurately established so 
that steps can be taken to restore critical body components to their original dimensions. An initial check can be carried 
out by means of drop checks or, preferably, trammels. Gauges are available which will accurately check for body twist.

Where repairs necessitate renewal of a critical body component it is recommended that a body jig is used.