Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual

							77PANEL REPAIRS
26
SEALING AND CORROSION PROTECTION FOAM/RUBBER SEAL APPLICATION AREAS
The following Illustrations show the location of foam/rubber seals. All areas
All areas symmetrically opposite to those shown are also treated.
Body side rear
M77 2093A
A
A
B
B
A - A
B - B
Section A-A shows a rubber seal in position on the body side rear upper assembly.
CAUTION: Ensure rubber seal is correctly seated into channel.
Section B-B shows a foam seal located on the bottom edge of the body side rear upper assembly. It is fixed to the
panel using double sided tape. 
						

							PANEL REPAIRS
27
SEALING AND CORROSION PROTECTION Body side lower
The arrows indicate the positon of two foam seals.
CAUTION: Ensure seals are fitted before refitting assembly. 
						

							77PANEL REPAIRS
28
SEALING AND CORROSION PROTECTION WATER LEAKS
Sealing charts in this section show those areas of the
bodyshell most likely to be affected by accident
damage and water leaks, and which could therefore
require re-treatment in repair. They do not show those
joint areas which only apply to factory assembly
operations and which are unlikely to be disturbed in
service (e.g. centre tunnel), or where the damage
would be so severe that the entire bodyshell would
normally be written off.
When water leakage occurs, always adopt a logical
approach to the problem using a combination of skill,
experience and intuition. Do not attempt to reach a
conclusion based only on visual evidence, such as
assuming that a leak emanates from the windscreen
because the footwell is wet. It will often be found that
the source of the leak is elsewhere. The correct
procedure will increase the chance of locating a leak,
however obscure it may seem.
Tools and Equipment
The following tools and equipment are recommended
for detection and rectification of water leaks:
1. Garden sprayer (hand-operated).
2. Wet/dry vacuum cleaner.
3. Dry absorbent cloths.
4. Battery torch.
5. Small mirror.
6. Weatherstrip locating tool.
7. Trim panel remover.
8. Small wooden or plastic wedges.
9. Dry compressed air supply.
10. Hot air blower.
11. Sealer applicators.
12. Ultrasonic leak detector.
During leak detection, the vehicle should be
considered in three basic sections:
The front interior space,
The rear passenger space (where
applicable), and
The rear loadspace or boot.Testing
From the information supplied by the customer it
should be possible for the bodyshop operator to locate
the starting point from which the leak may be
detected. After the area of the leak has been
identified, find the actual point of entry into the vehicle.
A simple and effective means initially is an ordinary
garden spray with provision for pressure and jet
adjustment. This will allow water to be directed in a jet
or turned into a fine spray. Use a mirror and a
battery-powered torch (NOT a mains voltage
inspection lamp) to see into dark corners.
The sequence of testing is particularly important. Start
at the lowest point and work slowly upwards, to avoid
testing in one area while masking the leak in another.
For example, if testing started at the level of the
windscreen, any water cascading into the plenum
chamber could leak through a bulkhead grommet and
into the footwells. Even at this point it could still be
wrongly assumed that the windscreen seal was at
fault.
Another important part of identifying a water leak is by
visual examination of door aperture seals, grommets
and weatherstrips for damage, deterioration or
misalignment, together with the fit of the door itself
against the seals.
Sealing
When the point of the leak has been detected,
proceed to rectify it using the following procedure:
1. Renew all door aperture seals and weatherstrips
which have suffered damage, misalignment or
deterioration.
2. Check all body seals to ensure that they are
correctly located on their mounting flanges/faces
using a locating tool if necessary.
3. Dry out body seams to be treated using
compressed air and/or a hot air blower as
necessary.
4. Apply sealant on the outside of the joint
wherever possible to ensure the exclusion of
water.
5. When rectifying leaks between a screen glass
and its weatherstrip (or in the case of direct
glazing, between the glass and bodywork), avoid
removing the glass if possible. Apply the
approved material either at the glass to
weatherstrip or glass to body. 
						

							PANEL REPAIRS
1
PANELS SERVICEABLE PANELS
Front end panels
1.Bonnet
2.Hinges
3.Bulkhead assembly 
						

							77PANEL REPAIRS
2
PANELS
4.Headlamp mounting panel - inner
5.Headlamp mounting panel - outer
6.Wing upper
7.Headlamp reinforcement panel
8.Wing lower 
						

							PANEL REPAIRS
3
PANELS Body side panels
9.’B/C’and’D’post assembly
10.Sill panel - front
11.Sill panel - rear 
						

							77PANEL REPAIRS
4
PANELS
12.Body side rear - upper
13.Body side cappings 
						

							PANEL REPAIRS
5
PANELS Rear end panels
14.Body side panel - lower
15.Body side panel - lower - assembly
16.Rear lamp panel
17.Rear panel
18.Rear floor 
						

							77PANEL REPAIRS
6
PANELS Door Assemblies
From 02MY the taildoor skin is one panel.
Roof 
						

							PANEL REPAIRS
1
PROCEDURES GENERAL WELDING PRECAUTIONS
The following pages show the procedures to follow
when using welding for repairs. No resistance spot
welds have been used in any of the repairs.
The Aluminium alloy used on all Defender models is a
combination of Aluminium and Magnesium.
When converting a MIG welder for use on Aluminium
it is essential the following components are changed.
The materials shown in brackets are the correct
materials to use:
Torch liner (Teflon or Carbon Fibre)
Contact tip
Feed rollers/wheels
Correct Filler wire (combination of
Aluminium and Magnesium)
Shielding gas (Argon)
When carrying out welding operations the following
criteria must be observed:
Where resistance spot welds have been
used in production, these must be replaced
with either MIG plug welds or rivets.
To replace each production spot weld an 8
mm (0.31 in) hole must be drilled and/or
punched, and a MIG weld then made in its
place. The number of plug welds must
match exactly the number of spot welds
which have been removed.
Where holes are left in an existing panel
after removal of the spot welds, a single
MIG plug weld will be made in each hole as
appropriate.
When MIG welding ensure the correct wire
is used.
The replacement welds in the welding
diagrams are denoted by the following
symbols:
A. MIG Plug welds
B. MIG seam weld
Seat Belt Anchorages
Seat belt anchorages are safety critical. When making
repairs in these areas it is essential to follow design
specifications.
Where possible, the original production assembly
should be used, complete with its seat belt
anchorages, or the cut line should be so arranged that
the original seatbelt anchorage is not disturbed.
All welds within 250mm (9.9in.) of seat belt
anchorages must be carefully checked for weld
quality, including spacing of spot welds. A crack
detection process must be carried out in these areas.
WARNING: Body parts incorporating seat
belt anchorages MUST be renewed
completely if damaged beyond repair, as
the welds in these areas are safety critical and
cannot be disturbed.