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 wax-injected areas which have been
disturbed during repairs, it is necessary to use a
compressed air spray gun with integral pressure cup
and a selection of interchangeable lances.
The following points must be observed during use,
according to the attachments fitted:
Use the rigid or flexible lance attachments
with 360°spray dispersal when treating
enclosed areas, to ensure maximum
coverage.
Where openings are restricted, use the
hook nozzle to provide a more directional
spray (e.g. inside narrow or short box
sections).
Spray exposed underbody surfaces directly
from the gun less lance attachment and
without disconnecting the fluid coupling.1100 mm (43.3in.) Rigid Lance:The nozzle on the
rigid lance produces a 360°circular spray pattern
combined with a forward-directed spray. Although wax
is distributed to all box section surfaces in a single
stroke, effective and complete coverage is best
achieved in long, straight structures and box section
cavities by spraying on both outbound and return
strokes of the lance.
The rigid lance also provides the positional accuracy
required in shaped sections, by allowing visual
assessment.
CAUTION: Do not force the lance into
access holes when using this attachment.
1100 mm (43.3in.) Flexible Nylon Lance:This lance
is similar in pattern to the rigid version, but provides
the additional penetration needed for curved sections
or in places where access is difficult. Its main
limitation is a lack of positional accuracy inside box
sections.
Carry out spraying on the outward stroke of the lance.
Withdraw the lance slowly to ensure sufficient
coverage.DO NOT withdraw the lance too quickly.
Keep the nylon tube of the lance away from the edges
of the access hole to eliminate abrasion and extend
the life of the tube. Take care to ensure that spraying
ceases just before the nozzle emerges from the
access hole. To assist this process, apply RED paint
to the final 30mm (1.2in.) of the nozzle. 
						

							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 accurately when it is concealed in a box
section or access hole.
For general spraying move the nozzle in an arc from
side to side, to ensure full coverage.
NOTE: Keep all wax injection/application
equipment clean. Use white spirit for this
purpose immediately after wax injection
operations.
Precautions during Body Repairs and Handling
Take care when handling the vehicle in the workshop.
PVC underbody sealers, seam sealers, underbody
wax and body panels may be damaged if the vehicle
is carelessly lifted.
Always follow the correct lifting, jacking and towing
procedures as shown inGENERAL INFORMATION
DATA, Information section, paying particular
attention to the following points:
Locate trolley jack pads properly before
lifting and lower the jack fully before
withdrawal.
Use only the approved hoisting points
when overhead hoisting is required.
Locate the lifting heads of wheel-free lifts
correctly, with rubber or similar material
placed between lifting head and
underbody.Steam Cleaning and Dewaxing
Due to the high temperatures generated by steam
cleaning equipment, there is a risk that certain trim
items could be damaged and some adhesives and
corrosion prevention materials softened or liquified.
Adjust the equipment so that the nozzle temperature
does not exceed 90°C (194°F). Take care not to allow
the steam jet to dwell on one area, and keep the
nozzle at least 300mm (11.8in.) from panel surfaces.
Do NOT remove wax or lacquer from underbody or
underbonnet areas during repairs. Should it be
necessary to steam clean these areas, apply a new
coating of wax or underbody protection as soon as
possible. 
						

							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 underbody wax to cover
the complete underfloor including
components but excluding brake discs,
exhaust system and propeller shafts.
A coat of protective lacquer applied to the
whole body.
A coat of protective wax applied to the
engine bay and wheel arch areas.
NOTE: Do not apply wax to engine bay of
Td5 models.
In addition to the above measures, all steel parts are
zinc-coated both sides.
Underbody Sealer
Underfloor areas and outer sill panels are treated with
a Plastisol PVC underbody sealer. This material is not
suitable for re-treatment.
When repairing areas of underbody sealer, strip the
factory-applied material back to a suitable break point,
ensuring that a clean metal surface is exposed and
that the edge of the existing material adheres soundly
to the panel.
Blanking plugs and grommets in the floor pan (except
those used for wax injection) MUST be fitted before
underbody sealer application. Heat-fusible plugs
which have been disturbed should either be refitted
with the aid of a hot air blower or replaced with rubber
grommets.
NOTE: Application of new underbody
sealer must be carried out between primer
and surfacer paint operations. Areas
where seam sealer is used should be re-treated as
necessary before application of underbody sealer.
CAUTION: Ensure that suspension units,
wheels, tyres, power unit, driveshafts,
exhaust and brakes (including all
mounting points) are shielded prior to application
of fresh underbody sealer.
Cavity Wax
Cavity wax is applied to certain box sctions The
information given on the following pages is intended
as a guide and shows the areas to be treated with
cavity wax, as well as the access holes used during
manufacture.See GENERAL INFORMATION DATA,
Sealing and corrosion protection section.
Underbody Wax
A coat of underbody wax is applied to the entire
underbody inboard of the sill vertical flanges, and
covers all moving and flexible components EXCEPT
for wheels and tyres, brakes and exhaust. The wax is
applied over paints and underbody sealers.
The underbody wax must be reinstated following all
repairs affecting floor panels.
CAUTION: Old underbody wax must be
completely removed from a zone
extending at least 200 mm (7.9 in) beyond
the area where new underbody sealer is to be
applied.
Engine Bay Wax
Reinstate protective engine bay wax disturbed during
repairs using the approved material.
Wheel Arch Wax
Reinstate protective wheel arch wax disturbed during
repairs using the approved material. 
						

							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 operations to
check bodywork for corrosion:
With the vehicle on a lift, carry out visual
check of underbody sealer for damage.
With the vehicle lowered, inspect exterior
paintwork for damage and body panels for
corrosion.
NOTE: Wash the vehicle and ensure that it
is free from deposits prior to inspection. It
is part of the owner’s responsibility to
ensure that the vehicle is kept free of
accumulations of mud which could accelerate the
onset of corrosion. The Dealer MUST wash the
vehicle prior to inspection of bodywork if the
customer has offered it in a dirty condition, and
pay special attention to areas where access is
difficult.
NOTE: The checks described above are
intended to be visual only. It is not
intended that the operator should remove
trim panels, finishers, rubbing strips or sound
deadening materials when checking the vehicle
for corrosion and paint damage.
With the vehicle on a lift, and using an inspection or
spot lamp, visually check for the following:
Corrosion damage and damaged
paintwork, condition of underbody sealer
on front and rear lower panels, sills and
wheel arches.
Damage to underbody sealer on main floor
and chassis members. Corrosion in areas
adjacent to suspension mountings and fuel
tank fixings.
NOTE: The presence of small blisters in
PVC underbody sealer is acceptable,
providing they do not expose bare metal.
Special attention must be paid to signs of damage
caused to panels or corrosion material by incorrect
jack positioning.
It is essential to follow the correct jacking and lifting
procedures.See GENERAL INFORMATION DATA,
Information section.
With the vehicle lowered, visually check for evidence
of damage and corrosion on all painted areas, in
particular the following:
Front edge of bonnet.
Visible flanges in engine compartment and
boot.
Lower body and door panels.
Where bodywork damage or evidence of corrosion is
found during inspection, rectify this as soon as is
practicable, both to minimise the extent of the damage
and to ensure the long term effectiveness of the
factory-applied corrosion protection treatment. Where
the cost of rectification work is the owner’s
responsibility, the Dealer must advise the owner and
endorse the relevant documentation accordingly.
Where corrosion has become evident and is
emanating from beneath a removable component
(e.g. trim panel, window glass, seat etc.), remove the
component as required to permit effective rectification. 
						

							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 wax,
PVC underbody sealer, sound deadening pads etc.
WARNING: DO NOT use oxy-acetylene gas
equipment to remove corrosion prevention
materials. Large amounts of fumes and
gases are liberated by these materials when they
burn.
Equipment for the removal of tough anti-corrosion
sealers offers varying degrees of speed and
effectiveness. The compressed air-operated scraper
(NOT an air chisel) offers a relatively quiet mechanical
method of removal using an extremely rapid
reciprocating action. During use, direct the operating
end of the tool along the work surface.
The most common method is by the use of a hot air
blower with integral scraper.
CAUTION: High temperatures can be
generated with this equipment which may
cause fumes. Always exercise care in its
use.
Another tool, and one of the most efficient methods, is
the rapid-cutting’hot knife’. This tool uses a wide
blade and is quick and versatile, able to be used
easily in profiled sections where access is otherwise
awkward.
Use the following procedure when repairing
underbody coatings:
1.Remove existing underbody coatings.2.After panel repair, clean the affected area with a
solvent wipe, and treat bare metal with an etch
phosphate material.
3.Re-prime the affected area.DO NOT under any
circumstances apply underbody sealer
directly to bare metal surfaces.
4.Replace all heat-fusible plugs which have been
disturbed. Use rubber grommets of equivalent
size if plugs are not available, but ensure that
they are embedded in sealer.
5.Mask off all mounting faces from which
mechanical components, hoses and pipe clips,
have been removed. Underbody sealer must be
appliedbeforesuch components are refitted.
6.Brush sealer into all exposed seams.
7.Spray the affected area with an approved
service underbody sealer.
8.Remove masking from component mating faces,
and touch-in where necessary. Allow adequate
drying time before applying underbody wax.
Underbody Wax
After refitting mechanical components, including
hoses, pipes and small fixtures, mask off the brake
discs and apply a coat of approved underbody wax.
NOTE: Where repairs include the
application of finish paint coats in the
areas requiring underbody wax, paint
operations must be carried out BEFORE wax
application.
Underbonnet Wax
Where repairs have involved replacement of engine
bay panels, treat the entire engine compartment
including all components, clips and small fixtures with
an approved underbonnet lacquer or wax.
Proprietary Anti-Corrosion Treatments
The application of proprietary anti-corrosion
treatments in addition to the factory-applied treatment
could invalidate the Corrosion Warranty and should be
discouraged. This does not apply to approved,
compatible, preservative waxes which may be applied
on top of existing coatings. 
						

							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 coating
brushed onto the surrounding area.
DO NOT affix unpainted metal surfaces of any
accessory directly to the vehicle bodywork unless they
are suitably protected. Where metal faces are bolted
together always interpose a suitable interface material
such as weldable zinc rich primer, extruded strip or
zinc tape. 
						

							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
extra holes for access where necessary, provided
these are not positioned in load-bearing members.
Ensure that such holes are treated with a suitable zinc
rich primer, brushed with wax and then sealed with a
rubber grommet.
Prior to wax injection, ensure that the cavity to be
treated is free from any contamination or foreign
matter. Where necessary, clear out any debris using a
compressed air supply.
Carry out wax injection after final paint operations.
During application, ensure that the wax covers all
flange and seam areas and that it is applied to all
repaired areas of both new and existing panels.
NOTE: Apply cavity wax AFTER the final
paint process and BEFORE refitting of any
trim components.It should also be noted that new panel assemblies and
body shells are supplied without wax injection
treatment which must be carried out after repairs.
Effective cavity wax protection is vital. Always observe
the following points:
Complete all finish paint operations before
wax application.
Clean body panel areas and blow-clean
cavities if necessary, before treatment.
Maintain a temperature of 18°C (64°F)
during application and drying.
Check the spray pattern of injection
equipment.
Mask off all areas not to be wax coated
and which could be contaminated by wax
overspray.
Remove body fixings, such as seat belt
retractors, if contamination is at all likely.
Move door glasses to fully closed position
before treating door interiors.
Treat body areas normally covered by trim
before refitting items.
Check that body and door drain holes are
clear after the protective wax has dried.
Keep all equipment clean, especially wax
injection nozzles. 
						

							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.