Land Rover Defender 1999 2002my Workshop Supplement Body Repair 3rd Edition Rover Manual

77PANEL REPAIRS
6
SEALING AND CORROSION PROTECTION Cavity wax application equipment and techniques
1. Air inlet
2. Flow control (spray pattern adjustment)
3. Pressure cup (1 litre [1.7 pt] capacity). Maximum
pressure 140 psi (9.7 bar, 9.8 kg/cm
2).
4. Gun connector
5. Lance nipple connection
6. Flexible lance
7. Rigid directional hook wand (forward cone spray
pattern)
8. Flexible nylon 1100mm (43.3in.) lance with
360°spray pattern
9. Rigid 1100mm (43.3in.) lance with 360°spray
pattern
When re-treating...

PANEL REPAIRS
7
SEALING AND CORROSION PROTECTION Hook Nozzle on Flexible Lance:The rigid hook
produces a highly atomised, forward-directed, fully
conical spray pattern having long range and good
dispersion characteristics. This combination has good
directional capabilities for the treatment of short,
narrow sections and may also be used for direct
spraying of inner wheel arches etc.
Position the flat area at the end of the lance at 180°to
the nozzle spray direction. This will help to guide the
spray more...

77PANEL REPAIRS
8
SEALING AND CORROSION PROTECTION CORROSION PROTECTION
The following information details the materials that are
applied during manufacture for corrosion protection.
Factory Treatments
The Defender is treated with the following
anti-corrosion materials in production:
A PVC-based underbody sealer material
which is sprayed onto the underfloor, wheel
arches and undersill areas.
An application of cavity wax which is
sprayed into enclosed cavities and box
sections.
A final coating of...

PANEL REPAIRS
9
SEALING AND CORROSION PROTECTION Stone Chip Resistant Paint/Primer
Re-treat all areas protected with factory-applied
anti-chip primer with suitable approved material in
repair.
Inspections during Maintenance Servicing
It is a requirement of the Land Rover Corrosion
Warranty that the vehicle body is checked for
corrosion by an authorised Land Rover dealer at least
once a year, to ensure that the factory-applied
protection remains effective.
Service Job Sheets include the following...

77PANEL REPAIRS
10
SEALING AND CORROSION PROTECTION Underbody Protection Repairs
When body repairs are carried out, always ensure that
full sealing and corrosion protection treatments are
restored. This applies both to the damaged area, and
also to areas where protection has been indirectly
impaired as a result of accident damage or repair
operations.
Prior to straightening out or panel beating, remove all
corrosion protection material in the damaged area.
This applies in particular to panels coated with...

PANEL REPAIRS
11
SEALING AND CORROSION PROTECTION Fitting Approved Accessories
When fitting accessories it is important that the
vehicle’s corrosion protection is not affected, either by
breaking the protective coating or by introducing a
moisture trap.
DO NOT screw self-tapping screws directly into the
body panel but fit plastic inserts first. Protect the
edges of holes drilled into panels, chassis members
and other body parts with a suitable zinc rich or acid
etch primer, followed by a protective wax...

77PANEL REPAIRS
12
SEALING AND CORROSION PROTECTION CAVITY WAX
Cavity Wax Injection
Box sections treated with cavity wax are shown in this
section. Repairs affecting these areas must include
re-treatment with an approved cavity wax, using the
access points illustrated. In addition, all interior
surfaces which have been disturbed during repairs
must be wax injected whether they have been treated
in production or not. This includes all box members,
cavities, door interiors etc. It is permissible to drill...

PANEL REPAIRS
13
SEALING AND CORROSION PROTECTION The following Illustrations show the treatment areas and Injection holes for Cavity Wax application.
All areas symmetrically opposite to those shown are also treated.
Bulkhead assembly
1
M77 2072A
B
A - A
B - B
2
A
A
B
Section A-A and B-B show application areas of cavity wax. Arrows 1 and 2 show application holes. 

77PANEL REPAIRS
14
SEALING AND CORROSION PROTECTION ’B/C’post assembly
1
M77 2073A
AA
BB
A - AB - B
2
Section A-A shows application area of cavity wax for the’B/C’post. Arrow 1 shows application hole.
Section B-B shows application area of cavity wax for the’D’post. Arrow 2 shows application hole. 

PANEL REPAIRS
15
SEALING AND CORROSION PROTECTION Front door
M77 2074A
B - B
2
2
2
2
1
A
B
B
A
2
A - A
Section A-A and B-B show application areas of cavity wax for the front door. Arrows 1 and 2 show the application
holes.