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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual
Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual
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77PANEL REPAIRS 26 SEALING AND CORROSION PROTECTION FOAM/RUBBER SEAL APPLICATION AREAS The following Illustrations show the location of foam/rubber seals. All areas All areas symmetrically opposite to those shown are also treated. Body side rear M77 2093A A A B B A - A B - B Section A-A shows a rubber seal in position on the body side rear upper assembly. CAUTION: Ensure rubber seal is correctly seated into channel. Section B-B shows a foam seal located on the bottom edge of the body side rear upper assembly. It is fixed to the panel using double sided tape.
PANEL REPAIRS 27 SEALING AND CORROSION PROTECTION Body side lower The arrows indicate the positon of two foam seals. CAUTION: Ensure seals are fitted before refitting assembly.
77PANEL REPAIRS 28 SEALING AND CORROSION PROTECTION WATER LEAKS Sealing charts in this section show those areas of the bodyshell most likely to be affected by accident damage and water leaks, and which could therefore require re-treatment in repair. They do not show those joint areas which only apply to factory assembly operations and which are unlikely to be disturbed in service (e.g. centre tunnel), or where the damage would be so severe that the entire bodyshell would normally be written off. When water leakage occurs, always adopt a logical approach to the problem using a combination of skill, experience and intuition. Do not attempt to reach a conclusion based only on visual evidence, such as assuming that a leak emanates from the windscreen because the footwell is wet. It will often be found that the source of the leak is elsewhere. The correct procedure will increase the chance of locating a leak, however obscure it may seem. Tools and Equipment The following tools and equipment are recommended for detection and rectification of water leaks: 1. Garden sprayer (hand-operated). 2. Wet/dry vacuum cleaner. 3. Dry absorbent cloths. 4. Battery torch. 5. Small mirror. 6. Weatherstrip locating tool. 7. Trim panel remover. 8. Small wooden or plastic wedges. 9. Dry compressed air supply. 10. Hot air blower. 11. Sealer applicators. 12. Ultrasonic leak detector. During leak detection, the vehicle should be considered in three basic sections: The front interior space, The rear passenger space (where applicable), and The rear loadspace or boot.Testing From the information supplied by the customer it should be possible for the bodyshop operator to locate the starting point from which the leak may be detected. After the area of the leak has been identified, find the actual point of entry into the vehicle. A simple and effective means initially is an ordinary garden spray with provision for pressure and jet adjustment. This will allow water to be directed in a jet or turned into a fine spray. Use a mirror and a battery-powered torch (NOT a mains voltage inspection lamp) to see into dark corners. The sequence of testing is particularly important. Start at the lowest point and work slowly upwards, to avoid testing in one area while masking the leak in another. For example, if testing started at the level of the windscreen, any water cascading into the plenum chamber could leak through a bulkhead grommet and into the footwells. Even at this point it could still be wrongly assumed that the windscreen seal was at fault. Another important part of identifying a water leak is by visual examination of door aperture seals, grommets and weatherstrips for damage, deterioration or misalignment, together with the fit of the door itself against the seals. Sealing When the point of the leak has been detected, proceed to rectify it using the following procedure: 1. Renew all door aperture seals and weatherstrips which have suffered damage, misalignment or deterioration. 2. Check all body seals to ensure that they are correctly located on their mounting flanges/faces using a locating tool if necessary. 3. Dry out body seams to be treated using compressed air and/or a hot air blower as necessary. 4. Apply sealant on the outside of the joint wherever possible to ensure the exclusion of water. 5. When rectifying leaks between a screen glass and its weatherstrip (or in the case of direct glazing, between the glass and bodywork), avoid removing the glass if possible. Apply the approved material either at the glass to weatherstrip or glass to body.
PANEL REPAIRS 1 PANELS SERVICEABLE PANELS Front end panels 1.Bonnet 2.Hinges 3.Bulkhead assembly
77PANEL REPAIRS 2 PANELS 4.Headlamp mounting panel - inner 5.Headlamp mounting panel - outer 6.Wing upper 7.Headlamp reinforcement panel 8.Wing lower
PANEL REPAIRS 3 PANELS Body side panels 9.’B/C’and’D’post assembly 10.Sill panel - front 11.Sill panel - rear
77PANEL REPAIRS 4 PANELS 12.Body side rear - upper 13.Body side cappings
PANEL REPAIRS 5 PANELS Rear end panels 14.Body side panel - lower 15.Body side panel - lower - assembly 16.Rear lamp panel 17.Rear panel 18.Rear floor
77PANEL REPAIRS 6 PANELS Door Assemblies From 02MY the taildoor skin is one panel. Roof
PANEL REPAIRS 1 PROCEDURES GENERAL WELDING PRECAUTIONS The following pages show the procedures to follow when using welding for repairs. No resistance spot welds have been used in any of the repairs. The Aluminium alloy used on all Defender models is a combination of Aluminium and Magnesium. When converting a MIG welder for use on Aluminium it is essential the following components are changed. The materials shown in brackets are the correct materials to use: Torch liner (Teflon or Carbon Fibre) Contact tip Feed rollers/wheels Correct Filler wire (combination of Aluminium and Magnesium) Shielding gas (Argon) When carrying out welding operations the following criteria must be observed: Where resistance spot welds have been used in production, these must be replaced with either MIG plug welds or rivets. To replace each production spot weld an 8 mm (0.31 in) hole must be drilled and/or punched, and a MIG weld then made in its place. The number of plug welds must match exactly the number of spot welds which have been removed. Where holes are left in an existing panel after removal of the spot welds, a single MIG plug weld will be made in each hole as appropriate. When MIG welding ensure the correct wire is used. The replacement welds in the welding diagrams are denoted by the following symbols: A. MIG Plug welds B. MIG seam weld Seat Belt Anchorages Seat belt anchorages are safety critical. When making repairs in these areas it is essential to follow design specifications. Where possible, the original production assembly should be used, complete with its seat belt anchorages, or the cut line should be so arranged that the original seatbelt anchorage is not disturbed. All welds within 250mm (9.9in.) of seat belt anchorages must be carefully checked for weld quality, including spacing of spot welds. A crack detection process must be carried out in these areas. WARNING: Body parts incorporating seat belt anchorages MUST be renewed completely if damaged beyond repair, as the welds in these areas are safety critical and cannot be disturbed.