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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 6 REPAIR CORNER CAPPING The Corner Capping is not replaced as a single panel. It is replaced in conjunction with either the Body Side Lower Panel or Body Side Assembly. The procedure to replace the Corner Capping is shown in the Body Side Lower Panel procedure. BODY SIDE CAPPING The Body Side Capping is not replaced as a single panel. It is replaced in conjunction with either the Body Side Lower Panel or Body Side Assembly. The procedure to replace the Body Side Capping is shown in the Body Side Lower Panel procedure. BODY SIDE REAR - UPPER Remove 1.Disconnect both battery leads, negative lead first. 2.Remove front, centre and rear sections of headlining. 3.Release upper edge of front door aperture seal. 4.Release upper edge of rear door aperture seal. 5.Remove fixings from front edge of roof, and along side being replaced. 6.Release sealant securing front edge of roof. 7.Insert wedges into top of both’B/C’posts. This will allow access for removal of body side. 8. RH side:Remove tail door.See CHASSIS AND BODY, Repair. 9.Remove side window. 10.Remove rear sixth light. 11.Remove all bolts securing upper body side. Refit 12.Prepare and clean panel joint faces. 13.Reverse removal procedure. NOTE: When refitting, ensure body side upper is correctly fitted onto location pins.
PANEL REPAIRS 7 REPAIR BODY SIDE REAR - LOWER - ASSEMBLY In this procedure the Body Side Capping and the Corner Capping are also changed. Remove 1.Disconnect both battery leads, negative lead first. 2.Remove body side upper rear.See this Section. 3.Remove all rear lamps and reflectors. 4. LH side:Remove number plate and lamp. 5. LH side:Remove tail door striker. 6. RH side:Remove fuel filler and grommet. 7.Remove all bolts and rivets securing lower body side assembly. Refit 8.Prepare and clean panel joint faces. 9.Reverse removal procedure. NOTE: When refitting, ensure body side upper is correctly fitted onto location pins.
77PANEL REPAIRS 8 REPAIR BODY SIDE REAR - PANEL Remove In this procedure the Body Side Capping and the Corner Capping are also changed. 1.Disconnect both battery leads, negative lead first. 2.Remove body side upper rear.See this Section. 3.Remove rear lamp panel.See this Section. 4. LH side:Remove number plate and lamp. 5. LH side:Remove tail door striker. 6. RH side:Remove fuel filler and grommet. Refit 7.Prepare and clean panel joint faces. Drill holes in new body side lower panel for riveting. Spacing of holes, dimension’A’= 100 mm (3.937’). In conjunction with the rivets apply suitable adhesive. 8.Prepare and clean panel joint faces. 9.Reverse removal procedure. NOTE: When refitting, ensure body side upper is correctly fitted onto location pins.
PANEL REPAIRS 9 REPAIR REAR LAMP PANEL Remove 1.Disconnect both battery leads, negative lead first. 2.Disconnect alternator. 3.Remove rear bench seat. 4. RH side:Remove tail door.See CHASSIS AND BODY, Repair. 5.Remove rear lights and reflector. 6. LH side:Remove number plate and tail door striker. Refit 7.Prepare and clean panel joint faces. 8.Reverse removal procedure.REAR CROSSMEMBER PANEL Remove 1.Disconnect both battery leads, negative lead first. 2.Remove both rear lamp panels.See this Section. Refit 3.Prepare and clean panel joint faces. 4.Reverse removal procedure.
77PANEL REPAIRS 10 REPAIR ROOF ASSEMBLY Remove 1.Disconnect both battery leads, negative lead first. 2.Remove rear bench seats. 3.Remove front, centre and rear sections of headlining. 4.Remove all bolts securing roof. NOTE: Carefully cut sealant securing front edge of roof to windscreen aperture. Refit 5.Prepare and clean panel joint faces. 6.Reverse removal procedure.
PANEL REPAIRS 11 REPAIR TIME SCHEDULES The following information shows the total time taken to replace single panels and complete assemblies. This time includes removal of Mechanical, Electrical and Trim (MET) items, plus paint times based on Metallic Clear Over Base Paint. The times shown were generated by Thatcham (the Motor Insurance Repair and Research Centre) and are to be used as a guide only. The operations were carried out on a 110 Station Wagon. Panel/assembly replacement times Panel Description Total time Bonnet 6.1 Bulkhead 24.2 Door front - each 7.8 Door rear - each 6.9 Door tail 7.7 Headlamp mounting panel LH 8.4 Headlamp mounting panel RH 8.3 Rear lamp mounting panel 9.3 Front screen aperture 7.4 Roof assembly 18.0 Sill and’B’post assembly LH 9.4 Sill and’B’post assembly RH 9.3 Sill panel - front section 4.2 Sill panel - rear section 4.1 Wing front lower 7.0 Wing front upper 8.7 Body side rear assembly - LH 16.7 Body side rear assembly - RH 17.7 Body side lower panel - LH 17.6 Body side lower panel - RH 18.6Combination panel replacement times The following panel combination times show the total time to remove/refit body panels, MET items and any paint processes. Front end combination panel times Panel Description Total Time Grille Bumper front Wheelarch eyebrow Wing - upper Wing - lower 12.7 LH 12.6 RH Grille Bumper front Wheelarch eyebrow LH & RH Wing - upper LH & RH Wing - lower LH & RH 18.2 Grille Bumper front Wheelarch eyebrow Wheelarch front Wing - upper Wing - lower 13.1 LH 13.0 RH Grille Bumper front Wheelarch eyebrow LH & RH Wheelarch front LH & RH Wing - upper LH & RH Wing - lower LH & RH 19.0
77PANEL REPAIRS 12 REPAIR Bodyside combination panel times Panel description Total time Front door Wheelarch eyebrow Wing - lower Wing - upper 15.4 LH 15.5 RH Front door Rear door Sill and’B’post 16.6 LH 16.5 RH Rear door Body side lower assembly Body side upper assembly Wheel arch eyebrow ’D’post outer reinforcement Corner capping Rear lamp panel 31.0 LH 32.1 RH Rear door Front door Wing lower Wing upper Body side lower assembly Body side upper assembly Wheel arch eyebrow - front & rear ’D’post outer reinforcement Corner capping Rear lamp panel 41.9 LH 42.8 RHRear end combination panel times Panel description Total time Corner capping Rear lamp panel 11.0 Body side lower assembly Body side upper assembly Wheel arch eyebrow ’D’post outer reinforcement Corner capping Rear lamp panel Rear panel 28.9 LH 29.9 RH Body side lower assembly Body side upper assembly Wheel arch eyebrow ’D’post outer reinforcement Corner capping Rear lamp panel Rear panel 28.5 LH 29.4 RH
PANEL REPAIRS 1 PAINT PAINT PROCEDURES Replacement Panels Service panels are supplied with a cathodic primer coating as part of the panel protection, and in compliance with the vehicle’s Corrosion Warranty where applicable.DO NOT remove this primer before paint refinishing. In the event of localised surface damage or imperfections, ensure that the minimum of primer is removed during rectification work for effective repair. Rectify damage by panel beating or straightening. To remove corrosion or paint runs on outer surfaces, abrade primer coat in the affected area as necessary using the following procedure: 1. Clean the panel using a solvent wipe. 2. Treat exposed areas of metal with an etch phosphate process. 3. Re-treat the affected area using either a separate acid-etch primer and two-pack surfacer, or an integrated etch primer/filler. Bolted Panels Before fitting bolt-on panels, ensure that all mating and adjacent surfaces on the vehicle and replacement panel are free from damage and distortion. Rectify if necessary as described in this section, and apply preformed strip sealer where specified.Welded Panels 1. Remove primer from the immediate vicinity of new and existing panel flanges, cleaning to bright metal finish. 2. On joints to be spot welded, apply weld-through zinc rich primer to joint faces of both flanges. Make spot welds while primer is still wet or according to the manufacturer’s instructions. 3. Dress accessible weld seams. 4. Clean panel using solvent wipe. 5. Treat bare metal with an etch phosphate process. 6. Re-treat repaired areas. NOTE: It is not satisfactory to use weld-through, zinc rich primers in conjunction with MIG welding. Sectioned Panels When replacing part or sectioned panels, the basic procedure is the same as for welded panels described above, with the following variations: 1. Remove primer from both new and existing joint faces, cleaning to a bright metal finish. 2. Where an overlap joint with the existing panel is to be spot welded, apply weld-through, zinc rich primer to both joint faces and spot weld while the primer is still wet or according to the manufacturer’s instructions. 3. MIG weld joints where applicable. 4. Clean the panel with a solvent wipe. 5. Treat bare metal areas using an etch phosphate process. 6. Re-prime affected areas as necessary as for rectifying transit damage.See this section. 7. Treat the inner faces of lap or butt joints with a suitable cavity wax.See Sealing and Corrosion Protection.