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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 3rd Edition Rover Manual
Land Rover Defender 1999 2002my Workshop Supplement Body Repair 3rd Edition Rover Manual
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77PANEL REPAIRS 2 INFORMATION Straightening Whenever possible, chassis 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. 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 body 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 differences in damage. Each repair is influenced by the extent of the damage and by the facilities and equipment available for its rectification. Most accident damage can be visually inspected and the approximate extent of the damage assessed. Sometimes deformation will extend beyond the area of direct damage, and the severity of this must be accurately established so that steps may be taken to restore critical body components to their original dimensions. An initial check of critical dimensions can be carried out by means of drop checks or (preferably) trammels. Gauges are available which will check accurately for body twist. Where repairs necessitate renewal of a critical body component it is recommended that a body jig is used.
PANEL REPAIRS 3 INFORMATION ELECTRONIC CONTROL UNITS (ECU’s) The ECU’s fitted to Defender vehicles make it advisable to follow suitable precautions prior to carrying out welding repair operations. All ECU’s must be diconnected before any welding operations take place. Harsh conditions of heat and vibration may be generated during these operations which could cause damage to the units.See ELECTRICAL PRECAUTIONS section.
PANEL REPAIRS 1 BODY DIMENSIONS CHASSIS AND BODY Chassis The chassis on all Defender variants are of the box section, ladder type construction, manufactured from 2 mm (14swg) steel and treated with zinc phosphate, cathodic electro coated, followed by waxing in the rear crossmember. Outriggers and angled brackets welded to the chassis support suspension and axle components and are also used as body mounting points. A detachable box section crossmember, located between the two chassis longitudinals is fitted to facilitate main gearbox and tranfer box assembly removal.Should chassis damage occur, a comprehensive range of components are available, including body support outriggers, cross members and radius arm mounting brackets. ALWAYS fit genuine parts that are fully guaranteed and to original equipment specification, fitted with Land Rover’s BS 5135 welding standard. Body All body panels, with the exception of the fascia bulkhead, are manufactured from aluminium alloy. Galvanized steel is used for the front wheel arches to give optimum protection. Most panels are also treated with zinc phosphate and cathodic electro coated with polyester surfacer, and are bolted to the welded chassis.
77PANEL REPAIRS 2 BODY DIMENSIONS CHASSIS FRAME ALIGNMENT With the vehicle assembled, a check for chassis squareness can be made as follows: 1.Place the vehicle on a level floor. 2.Mark measuring points at approximately the locations shown in LR4412M ensuring that the marks are exactly opposite on each side of the chassis frame.3.Hold a plumb line against each of the measuring points in turn and mark the floor directly beneath the plumb-bob. 4.Move the vehicle and measure diagonally between the marks made on the floor, if the chassis is square the diagonals between the related measuring points should be within 9,50 mm. 5.Chassis frame dimensional checks can be made, with the vehicle upper structure removed, referring to the applicable illustration and associated key.
PANEL REPAIRS 3 BODY DIMENSIONS LAND ROVER 90 CHASSIS
77PANEL REPAIRS 4 BODY DIMENSIONS LAND ROVER 90 CHASSIS ALIGNMENT DIMENSIONS A - Front Datum B - Chassis Datum C - Front axle centre line D - Rear axle centre line 1.239,0 - 236,5 mm 2.82,0 - 79,5 mm 3.633 mm 4.2420,6 - 2418,6 mm 5.2306,4 - 2305,4 mm 6.981,2 - 978,7 mm 7.182,7 mm 8.41,5 - 37,0 mm 9.252 - 250 mm10.110 mm 11.2360mm - Wheelbase 12.636 - 634 mm 13.488 - 482 mm 14.488 - 482 mm 15.3431,1 - 3426,1 mm 16.588,3 - 586,3 mm 17.2313,8 - 2311,8 mm 18.590,5 mm 19.295,25 mm 20.519,30 - 517,30 mm 21.259,80 - 258,50 mm 22.1242,6 - 1240,6 mm 23.642,5 - 639,5 mm24.750,9 mm 25.439,5 - 436,5 mm 26.136,5 mm 27.299,5 - 295,5 mm 28.103 - 100 mm 29.131,5 - 126,5 mm 30.705,5 - 704,5 mm 31.705,5 - 704,5 mm 32.42,2 - 40,2 mm 33.491 - 486 mm 34.594,2 - 593,4 mm 35.283,0 - 282,2 mm 36.32,25 - 31,25 mm 37.397 - 395 mm Engine mounting dimensions - section V-V Section V-V, Tdi and Td5 engine mounting bracket dimensions. The dimensions are applicable to all derivatives. Tdidimensions: A = 276.5 B = 553 C = 127.9 D = 317.4 E = 4 degreesTd5dimensions: A = 273.2 B = 546.5 C = 187.8 D = 374.3 E = 4 degrees
77PANEL REPAIRS 6 BODY DIMENSIONS LAND ROVER 110 CHASSIS ALIGNMENT DIMENSIONS A - Front Datum B - Chassis Datum C - Front axle centre line D - Rear axle centre line 1.4148 - 4143 mm 2.4009,5 - 4005 mm 3.978,7 - 981,2 mm 4.22 - 20 mm 5.252 - 250 mm 6.239 - 236,5 mm 7.3023,3 - 3022,3 mm 8.3030,7 - 3028,7 mm 9.155 - 153 mm 10.871,2 - 869,2 mm 11.2794 mm - Wheelbase 12.488 - 482 mm13.488 - 482 mm 14.82 - 79,5 mm 15.750,9 mm 16.750,9 mm 17.440,5 - 435,5 mm 18.440,5 - 435,5 mm 19.299,5 - 295,5 mm 20.500 - 495 mm 21.500 - 495 mm 22.594,2 - 593,4 mm 23.594,2 - 593,4 mm 24.283 - 282,2 mm 25.283 - 282,2 mm 26.1970 - 1968 mm 27.642,9 - 639,5 mm 28.750,9 mm29.290,5 mm 30.295,5 mm 31.299,5 - 295,5 mm 32.103 - 100 mm 33.1177,5 - 1175,5 mm 34.1692,5 - 1689,5 mm 35.2610 - 2606 mm 36.2040,5 - 2037,5 mm 37.1912,5 - 1909,5 mm 38.1359 - 1357 mm 39.1573 - 1571 mm 40.270 - 268 mm 41.665,5 - 663,5 mm 42.440 - 438 mm 43.32,25 - 31,25 mm Section V-V is through the engine mountings. Dimensional information for the mountings can be found in Land Rover’90’engine mounting dimensions.