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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. 
    						
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