Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual

77PANEL REPAIRS
6
REPAIR CORNER CAPPING
The Corner Capping is not replaced as a single panel.
It is replaced in conjunction with either the Body Side
Lower Panel or Body Side Assembly. The procedure
to replace the Corner Capping is shown in the Body
Side Lower Panel procedure.
BODY SIDE CAPPING
The Body Side Capping is not replaced as a single
panel. It is replaced in conjunction with either the
Body Side Lower Panel or Body Side Assembly. The
procedure to replace the Body Side Capping is shown
in the...

PANEL REPAIRS
7
REPAIR BODY SIDE REAR - LOWER - ASSEMBLY
In this procedure the Body Side Capping and the
Corner Capping are also changed.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove body side upper rear.See this
Section.
3.Remove all rear lamps and reflectors.
4. LH side:Remove number plate and lamp.
5. LH side:Remove tail door striker.
6. RH side:Remove fuel filler and grommet.
7.Remove all bolts and rivets securing lower body
side assembly.
Refit
8.Prepare and clean panel...

77PANEL REPAIRS
8
REPAIR BODY SIDE REAR - PANEL
Remove
In this procedure the Body Side Capping and the
Corner Capping are also changed.
1.Disconnect both battery leads, negative lead
first.
2.Remove body side upper rear.See this
Section.
3.Remove rear lamp panel.See this Section.
4. LH side:Remove number plate and lamp.
5. LH side:Remove tail door striker.
6. RH side:Remove fuel filler and grommet.
Refit
7.Prepare and clean panel joint faces. Drill holes in
new body side lower panel for riveting....

PANEL REPAIRS
9
REPAIR REAR LAMP PANEL
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect alternator.
3.Remove rear bench seat.
4. RH side:Remove tail door.See CHASSIS
AND BODY, Repair.
5.Remove rear lights and reflector.
6. LH side:Remove number plate and tail door
striker.
Refit
7.Prepare and clean panel joint faces.
8.Reverse removal procedure.REAR CROSSMEMBER PANEL
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove both rear lamp panels.See this
Section....

77PANEL REPAIRS
10
REPAIR ROOF ASSEMBLY
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove rear bench seats.
3.Remove front, centre and rear sections of
headlining.
4.Remove all bolts securing roof.
NOTE: Carefully cut sealant securing front
edge of roof to windscreen aperture.
Refit
5.Prepare and clean panel joint faces.
6.Reverse removal procedure. 

PANEL REPAIRS
11
REPAIR TIME SCHEDULES
The following information shows the total time taken to
replace single panels and complete assemblies. This
time includes removal of Mechanical, Electrical and
Trim (MET) items, plus paint times based on Metallic
Clear Over Base Paint.
The times shown were generated by Thatcham (the
Motor Insurance Repair and Research Centre) and
are to be used as a guide only. The operations were
carried out on a 110 Station Wagon.
Panel/assembly replacement times
Panel Description...

77PANEL REPAIRS
12
REPAIR Bodyside combination panel times
Panel description Total time
Front door
Wheelarch eyebrow
Wing - lower
Wing - upper
15.4 LH
15.5 RH
Front door
Rear door
Sill and’B’post
16.6 LH
16.5 RH
Rear door
Body side lower assembly
Body side upper assembly
Wheel arch eyebrow
’D’post outer reinforcement
Corner capping
Rear lamp panel
31.0 LH
32.1 RH
Rear door
Front door
Wing lower
Wing upper
Body side lower assembly
Body side upper assembly
Wheel arch eyebrow - front & rear
’D’post outer...

PANEL REPAIRS
13
REPAIR 

PANEL REPAIRS
1
PAINT PAINT PROCEDURES
Replacement Panels
Service panels are supplied with a cathodic primer
coating as part of the panel protection, and in
compliance with the vehicle’s Corrosion Warranty
where applicable.DO NOT remove this primer
before paint refinishing. In the event of localised
surface damage or imperfections, ensure that the
minimum of primer is removed during rectification
work for effective repair.
Rectify damage by panel beating or straightening. To
remove corrosion or paint...