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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual
Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual
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77PANEL REPAIRS 8 BODY DIMENSIONS LAND ROVER 130 CHASSIS ALIGNMENT DIMENSIONS A - Front Datum B - Chassis Datum C - Front axle centre line D - Rear axle centre line E - Chassis Datum, section A - A 1.633,0 mm reference only 2.3569,3 - 3567,3 mm 3.2421,8 - 2419,8 mm 4.2317,5 - 2314,5 mm 5.2188,3 - 2185,3 mm 6.2119,5 - 2117,3 mm7.1990 - 1988 mm 8.1970 - 1968 mm 9.2401,8 - 2399,8 mm 10.110,0 mm reference 11.149,7 - 146,7 mm reference dimension 12.3225.8 mm - Wheelbase NOTE: The above dimensions are for the Land Rover 130 chassis frame. For additional measurements, refer to the Land Rover 110 chassis frame drawing and aligment dimensions.
PANEL REPAIRS 9 BODY DIMENSIONS GAP AND PROFILE INFORMATION The following information is to be used as a guide to assist the technician in refitting exterior body panels and trim items, to achieve a correctly aligned and cosmetically acceptable vehicle. Section A-A, Bonnet to wing, gap A = 3 - 8 mm. To be parallel within 2 mm. Section B-B, Wing to’A’post lower, gap B = 0. Profile = +/- 1 mm. Section C-C, Wing to sill, gap C = 0. Profile = +/- 1 mm. Section D-D, Screen aperture to door frame, gap D = 5 - 9 mm. Section E-E, Door frame to roof, gap E = 7 - 11 mm. Section F-F, Front and rear door to’B/C’post, gap F = 7 - 11 mm.
77PANEL REPAIRS 10 BODY DIMENSIONS Section G-G, Door to sill, gap G = 7 - 11 mm. Door profile to sill = 0 to + 2 mm. Section H-H, Rear door to body, gap H = 7 - 11 mm. Door profile to body = 0 to + 3 mm. Section J-J, Body side lower to body, gap J = 0 - 4 mm. To be parallel within 2 mm.
PANEL REPAIRS 11 BODY DIMENSIONS Section K-K, Roof to taildoor, gap K = 7 - 9 mm. Profile = +/- 1 mm. Section L-L, N-N, Body side to taildoor, gap L = 5 - 7 mm. Profile = +/- 1 mm. Section M-M, Body rear to taildoor, gap M = 7 - 9 mm.
PANEL REPAIRS 1 SEALING AND CORROSION PROTECTION APPROVED MATERIALS Joint types: 1. Between bolted panels 2. Between bolted panel edges 3. Between spot welded panels 4. Between spot welded panel edges 5. Between bonded panels 6. Between bonded panel edges7. Clinch joints (type a) 8. Clinch joints (type b) 9. Clinch joints (type c) 10. Gaps between panels (type a) 11. Gaps between panels (type b) 12. Lap joint
77PANEL REPAIRS 2 SEALING AND CORROSION PROTECTION DESCRIPTION - USEAGE SUPPLIER PART NUMBER CAVITY WAXES Inner Cavity Wax (Transparent) 3M (08909, 08919, 08929) Inner Cavity Wax (Amber) 3M (08901, 08911, 08921) Cavity Wax Croda (PW57) ENGINE BAY WAXES/LACQUERS Astrolan engine bay wax and Cosmetic Wax Astors DA3243/1 Engine Bay Cosmetic Wax/Lacquer Croda PW197 Engine Bay Cosmetic Wax/Lacquer Dinol 4010 MISCELLANEOUS MATERIALS Flexible Parts Repair Material - rubber modified polypropylene parts3M: (05900) Aerosol Auto’Adhesive (trim) - impact adhesive for trim parts 3M (08080) Water Shedder Repair Teroson: Sound dampening foam Gurit Essex: Betacore 7999 SEAM SEALERS Body Caulking - type (b) gaps between panels 3M 08568 Drip Chek Clear - bolted, spot welded and bonded panel edges; type (a) and (b), gaps between panels; type (c) clinch joints3M 08401 Drip Chek Heavy - type (b) gaps between panels; type (c) clinch joints3M 08531 Flexseal Polyurethane Seam Sealer - bolted, spot welded and bonded panel edges; type (a) and (b) gaps between panels; type (b) clinch joints3M (08684, 08689, 08694) Polyurethane Sealer (sachet) 3M (08703, 08783, 08788) Sprayable Sealer - type 12 lap joints 3M (08800, 08823) Super Seam Sealer - type 12 lap joints 3M (08537) Weld Thru’Sealer - between spot welded panels 3M (08625) Betafill Clinch and Brushable Sealer (Black, Grey, White) Gurit Essex 10211/15/20 Clinch Joint and Underbody Coating (Grey, Beige) Gurit Essex (10101, 10707) Leak-Chek Clear - between bolted panels; spot welded and bonded panel edges; type (c) clinch jointsKent Industries (10075) Putty - type (a) and (b) gaps between panels Kent Industries Polyurethane Seam Sealer between bolted panels; spot welded and bonded panel edges; type (a) and (b) gaps between panelsPPG (6500) Polyurethane Seam Sealer between bolted panels; spot welded and bonded panel edges; type (a) and (b) gaps between panelsTeroson 92
PANEL REPAIRS 3 SEALING AND CORROSION PROTECTION DESCRIPTION - USEAGE SUPPLIER PART NUMBER SEAM SEALERS - continued Terolan Light Seam Sealer - bolted, spot welded and bonded panel edges; type (a) and (b) gaps between panels; between bonded panels; type (c) clinch jointsTeroson Terolan Special Brushable Seam Sealer - lap joints 12 Teroson Terostat Sprayable Seam Sealer - bolted, spot welded and bonded panel edges; between bonded panels; type (a) and (b) gaps between panelsTeroson 9320 Terostat 1K PU Seam Sealer (SE 20) - type (a) and (b) gaps between panels; spot welded and bonded panel edgesTeroson Sealing compound - bolted, spot welded and bonded panel edges; type (b) gaps between panelsWurths 8901001/-/6 STRUCTURAL ADHESIVES Automotive Structural Adhesive - between bonded panels; type 5 and 73M 08122 Two part Structural Epoxy - between bonded and spot welded panels; type (a) clinch jointsCiba - Geigy XB5106/7 UNDERBODY SEALERS Body Schutz 3M 08861 Spray Schutz 3M 08877 Crodapol Brushable Sealer Croda PV75 Terotex Underseal (CP02) Teroson 9320 UNDERBODY WAXES Stone chip coating (smooth) 3M 08158/9 Underbody Wax Croda PW61 Underbody Wax Dinol Tectacote 205 WELD-THROUGH PRIMERS Weld-thru’coating 3M 05913 Zinc Spray 3M 09113 Zinc Rich Primer ICI P-565 634
77PANEL REPAIRS 4 SEALING AND CORROSION PROTECTION APPLICATION EQUIPMENT SATA Schutz Gun Model UBE Specifications: Air consumption 200 litres/min. (7 ft 3/min.) @ 45 psi ............................................................... Weight 660grams (23.3oz).............................................................................. Manufactured and supplied by: Sata Gmbh Minden Industrial Ltd. 16 Greyfriars Road Moreton Hall Bury St. Edmunds Suffolk IP32 7DX Tel. (01284) 760791 The Sata Schutz Gun is approved for the re-treatment of vehicle underbody areas with protective coatings as supplied in 1-litre (1.76pt.), purpose-designed, ’one-way’containers. The screw thread fitting (female on the gun) will fit most Schutz-type packs. Full operating details are supplied with the equipment. NOTE: Always clean gun after use with the appropriate solvent. Sata HKD1 Wax Injection Equipment The Sata HKD1 is approved by Land Rover for use in all cavity wax re-treatment operations. The equipment comprises a high quality forged gun with 1-litre capacity pressure feed container, a flexible nylon lance, 1100 mm (43.3 in) straight steel lance and hooked wand lance. A quick-change coupling is a standard fitting to enable lances to be easily interchanged. The lances each have their own spray pattern characteristics to suit the type of box section to be treated. The Sata HKD1 is covered by a 12 month warranty. All replacement parts and service are obtainable from the suppliers.
PANEL REPAIRS 5 SEALING AND CORROSION PROTECTION Cooper Pegler Falcon Junior Pneumatic (Airless) Manufacturer and supplier: Cooper Pegler & Co. Ltd. Burgess Hill Sussex RH15 9LA Tel. 04 446 42526 Intended primarily for applying transit wax, the Falcon Junior pneumatic sprayer has a 5-litre (1 gal.) container with integral hand pump. This high quality unit provides a simple and effective means of wax spraying without the need for compressed air or additional services. A selection of nozzles, lances and hoses together with a trigger valve assembly incorporating a filter enable the sprayer to be used in a variety of applications. These include general maintenance, wax injection and paint application. All parts are fully replaceable and include a wide range of nozzle configurations. The Falcon Junior is fitted with Viton seals and is guaranteed for 12 months.3M Application Equipment Manufacturer: 3M UK PLC Automotive Trades Group 3M House PO Box 1 Market Place Bracknell Berks. RG12 1JU Tel. (01344) 858611 All 3M equipment is available from local trade factors or 3M refinishing factors. 3M Caulking Gun 08002 A lightweight, robust metal skeleton gun designed to accommodate 325 mm (12.8 in) cartridge for dispensing sealants etc. This gun facilitates rapid cartridge loading and features a quick-release lever for accurate material ejection and cut-off control. 3M Pneumatic Cartridge Gun 08012 An air line fed gun for application of 3M cartridge products. Excellent ease of application for a smooth sealant bead, and incorporates a regulator valve for additional control. Other 3m applicator equipment available: 3M Pneumatic Applicator Guns Air line fed gun for application of 3M sachet sealers (Part No. 08006 for 200 ml (6 fl oz) and 310 ml (9 fl oz) sachets, and Part No. 08007 for all size sachets including 600 ml (18 fl oz). 3M Applicator Gun 08190 For application of 3M Structural Adhesive 08120. 3M Inner Cavity Wax Applicator Gun Features 750 mm (29.6 in) flexible tube and using 1-litre (1.76 pt) canisters, this approved equipment is available from all 3M refinishing factors. Other 3m applicator equipment available: Heavy Duty Manual Gun.