LAND ROVER DEFENDER 1999 Workshop Manual

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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.
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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.
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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.
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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.
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BODY DIMENSIONS
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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
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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
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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
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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.
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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.
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