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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. 
    						
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