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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 PROCEDURES PANEL REPLACEMENT PROCEDURE General This information is designed to explain the basic panel removal and replacement method. This standard method may vary slightly from one vehicle to another. The main criterion in removal and replacement of body panels is that Land Rover’s original standard is maintained as far as possible. All repair processes and procedures shown relate to Aluminium panels. Remove Panel 1.Expose resistance spot welds. For those spot welds which are not obviously visible, use a rotary drum sander or wire brush fitted to an air drill, or alternatively a hand held wire brush. WARNING: Ensure breathing mask and protective glasses are worn during operations where Aluminium particles are removed. CAUTION: Never use a sanding disc that has previously been used on steel, as iron deposits could be left on the surface of the Aluminium. NOTE: In wheel arch areas it may be necessary to soften underbody coating using a hot air gun, prior to exposing spot welds. 2.Cut out welds using a cobalt drill. 3.Alternatively use a clamp-type spot weld remover.
PANEL REPAIRS 3 PROCEDURES 4.Cut away the bulk of the panel as necessary using an air saw. NOTE: On certain panel joints MIG welds and braze should be removed using a sander where possible, before cutting out the panel bulk. 5.Separate spot welded joints and remove panel remnants using hammer, bolster chisel and pincers.Prepare Old Surfaces 6.Clean all panel joint edges to a bright smooth finish, using a belt-type sander. NOTE: Prior to sanding, remove remaining sealant using a hot air gun to minimise the risk of toxic fumes caused by generated heat. WARNING: Care must be taken to avoid excessive heat build up which may be caused by this equipment. 7.Straighten existing joint edges using shaping block and hammer. CAUTION: Where significant straightening is required, heat must be applied to the area to avoid stretching the Aluminium. CAUTION: All tools used for working with Aluminium must be kept separate from those used on steel.
77PANEL REPAIRS 4 PROCEDURES Prepare New Surfaces 8.Prepare new panel joint edges for welding by sanding to a bright finish. This must include inner as well as outer faces. 9.Drill holes in new panel, in the equivalant spot weld positions. 10.Apply adhesive sealant to panel joint surfaces. 11.All mating faces that have sealant applied to them must be cleaned using a suitable solvent. The majority of Aluminium sealants have a primer/pre-treatment included with them. CAUTION: Do not use Petroleum Spirit, Alcohol or Paint Thinners to clean mating faces.Offer Up and Align Offer up new panel and align with associated panels. Clamp into position using welding clamps or Mole grips. Where a joggle or brace joint is being adopted, make a set in the original panel joint edge or insert a brace behind the joint. NOTE: In cases where access for welding clamps is difficult, it may be necessary to use tack welds. 12.Dress MIG tack welds using a sander with 36 grit disc, or a belt-type sander where access is limited.
PANEL REPAIRS 5 PROCEDURES Welding 13.When plug welding, begin weld approximately 15 mm (0.6’) from hole. This will allow the weld area to be preheated which will enhance weld penetration. It also allows the operator to see more easily where penetration takes place. Fill hole with weld by moving in a circular direction around the hole. 14.When MIG seam welding do not carry out lengthy operations. Divide the welds into short operations, this will reduce the chances of overheating the workpiece which inturn will avoid distortion and strain. 15.Dress all welds using a sander with 36 grit disc, or a belt-type sander and/or wire brush. CAUTION: Only use a Stainless Steel wire brush for Aluminium.
77PANEL REPAIRS 6 PROCEDURES REPAIR PROCEDURES Body Trim The following panel repair operations itemise body trim components which must be removed for access during each repair.See Repairs section. Because of the unpredictable nature of accident damage, the items listed make no allowance for any difficulties which may be found in removal and only apply to an undamaged vehicle. No allowance is made for any difficulties which may be found during panel removal. Damaged body trim items must be renewed as necessary following body repairs.
PANEL REPAIRS 1 REPAIR WING LOWER FRONT Remove 1.Disconnect both battery leads, negative lead first. system. 2.Remove wheel arch eyebrow. 3.Remove wheel arch liner. 4. RH side:Remove aerial. 5.Remove air intake hose. 6.Remove bolts securing lower wing. Refit 7.Prepare and clean panel joint faces. 8.Reverse removal procedure.HEADLAMP MOUNTING PANEL Remove 1.Disconnect both battery leads, negative lead first. 2.Disconnect all ECUs. 3.Remove radiator.See COOLING SYSTEM, Repair. 4.Recover refrigerant from A/C system.See AIR CONDITIONING, Repair. 5.Remove headlamp.See ELECTRICAL, Repair. 6. LH side:Remove screen washer bottle.See WIPERS AND WASHERS, Repair. 7. RH side:Position PAS reservoir aside. 8.Remove bolts and release welds securing panel, remove panel. Refit 9.Prepare and clean panel joint faces. Punch or drill holes in new panel for plug welding as shown. 10.Reverse removal procedure.
77PANEL REPAIRS 2 REPAIR WING UPPER - LH Remove 1.Disconnect both battery leads, negative lead first. 2.Remove headlamp.See ELECTRICAL, Repair. 3.Remove headlamp mounting panel.See this Section. 4.Remove radiator.See COOLING SYSTEM, Repair. 5.Recover refrigerant from A/C system.See AIR CONDITIONING, Repair. 6.Remove receiver drier.See AIR CONDITIONING, Repair. 7.Remove relevant A/C pipes. 8.Remove relevant heater intake pipes. 9.Remove screen washer bottle. 10.Remove wheel arch liner.See CHASSIS AND BODY, Repair. 11.Remove bolts and release welds securing panel, remove panel. Refit 12.Prepare and clean panel joint faces. 13.Reverse removal procedure. 14.Align headlamps.See ELECTRICAL, Adjustment.WING UPPER - RH Remove 1.Disconnect both battery leads, negative lead first. 2.Remove headlamp.See ELECTRICAL, Repair. 3.Remove headlamp mounting panel.See this Section. 4.Remove radiator.See COOLING SYSTEM, Repair. 5.Recover refrigerant from A/C system.See AIR CONDITIONING, Repair. 6.Remove relevant A/C pipes. 7.Position PAS reservoir aside. 8.Remove wheel arch liner.See CHASSIS AND BODY, Repair. 9.Remove aerial. 10.Remove vacuum solenoid valve. 11.Release clips securing coolant reservoir. 12.Remove bolts and release welds securing panel, remove panel. Refit13.Prepare and clean panel joint faces. NOTE: LH panel shown 14.Reverse removal procedure. 15.Align headlamps.See ELECTRICAL, Adjustment.
PANEL REPAIRS 3 REPAIR WHEEL ARCH - FRONT Remove The procedure to change the Inner Front Wheelarch is the same as for the Wing Upper, except for removal of the ABS sensors and shield, if fitted. BULKHEAD ASSEMBLY Remove 1.Disconnect both battery leads, negative lead first. 2.Remove front lower wing.See this Section. 3.Remove RH and LH front upper wing.See this Section. 4.Remove headlamp mounting panels.See this Section. 5.Remove screen aperture.See this Section. 6.Remove both front doors. 7.Remove lower fascia panel.See CHASSIS AND BODY, Repair. 8. Models with A/C:Remove relevant A/C pipes. 9.Remove front grille. 10.Drain cooling system.See COOLING SYSTEM, Adjustment. 11.Remove radiator and intercooler. 12. Models with A/C:Remove condensor. 13.Remove air cleaner assembly. 14.Remove heater unit.See HEATING AND VENTILATION, Repair. 15.Remove brake servo assembly. 16.Remove heater ducts. 17.Remove both front seats. 18.Remove front carpets. 19.Release all relevant harnesses and position aside. 20.Remove facia support bracket. Refit 21.Prepare and clean panel joint faces. Ensure all necessary grommets and sealant is applied to new bulkhead. 22.Reverse removal procedure. 23.Bleed brake system.See BRAKES, Adjustment. 24.Align headlamps.See ELECTRICAL, Adjustment. 25.Water test after refitting.
77PANEL REPAIRS 4 REPAIR SCREEN APERTURE Remove 1.Disconnect both battery leads, negative lead first. 2.Raise side of vehicle. 3.Remove front and centre headlining sections. 4.Remove both’A’post upper trims. 5.Remove front door aperture seals. 6.Release upper front corner of rear door aperture seal. 7.Remove both wiper arms.See WIPERS AND WASHERS, Repair. 8.Remove front screen. 9.Remove all roof fixings, back to the’B/C’post. 10.Release sealant securing front edge of roof. 11.Insert wedges into top of both’B/C’posts. This will allow access for removal of screen aperture. 12.With assistance remove screen aperture.Refit 13.Prepare and clean panel joint faces. 14.Reverse removal procedure. Fit new foam seal to top edge of aperture. NOTE: When refitting, ensure screen aperture is correctly fitted onto location pins in bulkhead. 15.When applying sealant to top edge of aperture, the correct colour sealant must be used, see note below. NOTE: White roof vehicles use a white sealant. Coloured roof vehicles use a black sealant.
PANEL REPAIRS 5 REPAIR SILL - FRONT Remove NOTE: The procedure to replace the rear sill section is the same as the front. 1.Remove bolts securing sill to body, discard seal. Refit NOTE: Front sill NOTE: Rear sill 2.Prepare and clean panel joint faces. Refit new seal. 3.Reverse removal procedure.’B/C’&’D’POST Remove 1.Disconnect both battery leads, negative lead first. 2.Remove rear door and striker. 3.Remove front seat belt reel.See CHASSIS AND BODY, Repair. 4.Remove front and rear carpets. 5.Remove front seat. 6.Remove rear seat. 7.Remove front, centre and rear sections of headlining. NOTE: Assembly is held on with bolts. Refit 8.Prepare and clean panel joint faces. 9.Reverse removal procedure.