wheel LAND ROVER DEFENDER 1999 Owners Manual

77PANEL REPAIRS
6
BODY DIMENSIONS LAND ROVER 110
CHASSIS ALIGNMENT DIMENSIONS
A - Front Datum
B - Chassis Datum
C - Front axle centre line
D - Rear axle centre line
1.4148 - 4143 mm
2.4009,5 - 4005 mm
3.978,7 - 981,2 mm
4.22 - 20 mm
5.252 - 250 mm
6.239 - 236,5 mm
7.3023,3 - 3022,3 mm
8.3030,7 - 3028,7 mm
9.155 - 153 mm
10.871,2 - 869,2 mm
11.2794 mm - Wheelbase
12.488 - 482 mm13.488 - 482 mm
14.82 - 79,5 mm
15.750,9 mm
16.750,9 mm
17.440,5 - 435,5 mm
18.440,5 - 435,5 mm
19.299,5 - 295,5 mm
20.500 - 495 mm
21.500 - 495 mm
22.594,2 - 593,4 mm
23.594,2 - 593,4 mm
24.283 - 282,2 mm
25.283 - 282,2 mm
26.1970 - 1968 mm
27.642,9 - 639,5 mm
28.750,9 mm29.290,5 mm
30.295,5 mm
31.299,5 - 295,5 mm
32.103 - 100 mm
33.1177,5 - 1175,5 mm
34.1692,5 - 1689,5 mm
35.2610 - 2606 mm
36.2040,5 - 2037,5 mm
37.1912,5 - 1909,5 mm
38.1359 - 1357 mm
39.1573 - 1571 mm
40.270 - 268 mm
41.665,5 - 663,5 mm
42.440 - 438 mm
43.32,25 - 31,25 mm
Section V-V is through the engine mountings. Dimensional information for the mountings can be found in Land
Rover’90’engine mounting dimensions.
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77PANEL REPAIRS
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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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PANEL REPAIRS
7
SEALING AND CORROSION PROTECTION Hook Nozzle on Flexible Lance:The rigid hook
produces a highly atomised, forward-directed, fully
conical spray pattern having long range and good
dispersion characteristics. This combination has good
directional capabilities for the treatment of short,
narrow sections and may also be used for direct
spraying of inner wheel arches etc.
Position the flat area at the end of the lance at 180°to
the nozzle spray direction. This will help to guide the
spray more accurately when it is concealed in a box
section or access hole.
For general spraying move the nozzle in an arc from
side to side, to ensure full coverage.
NOTE: Keep all wax injection/application
equipment clean. Use white spirit for this
purpose immediately after wax injection
operations.
Precautions during Body Repairs and Handling
Take care when handling the vehicle in the workshop.
PVC underbody sealers, seam sealers, underbody
wax and body panels may be damaged if the vehicle
is carelessly lifted.
Always follow the correct lifting, jacking and towing
procedures as shown inGENERAL INFORMATION
DATA, Information section, paying particular
attention to the following points:
Locate trolley jack pads properly before
lifting and lower the jack fully before
withdrawal.
Use only the approved hoisting points
when overhead hoisting is required.
Locate the lifting heads of wheel-free lifts
correctly, with rubber or similar material
placed between lifting head and
underbody.Steam Cleaning and Dewaxing
Due to the high temperatures generated by steam
cleaning equipment, there is a risk that certain trim
items could be damaged and some adhesives and
corrosion prevention materials softened or liquified.
Adjust the equipment so that the nozzle temperature
does not exceed 90°C (194°F). Take care not to allow
the steam jet to dwell on one area, and keep the
nozzle at least 300mm (11.8in.) from panel surfaces.
Do NOT remove wax or lacquer from underbody or
underbonnet areas during repairs. Should it be
necessary to steam clean these areas, apply a new
coating of wax or underbody protection as soon as
possible.
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77PANEL REPAIRS
8
SEALING AND CORROSION PROTECTION CORROSION PROTECTION
The following information details the materials that are
applied during manufacture for corrosion protection.
Factory Treatments
The Defender is treated with the following
anti-corrosion materials in production:
A PVC-based underbody sealer material
which is sprayed onto the underfloor, wheel
arches and undersill areas.
An application of cavity wax which is
sprayed into enclosed cavities and box
sections.
A final coating of underbody wax to cover
the complete underfloor including
components but excluding brake discs,
exhaust system and propeller shafts.
A coat of protective lacquer applied to the
whole body.
A coat of protective wax applied to the
engine bay and wheel arch areas.
NOTE: Do not apply wax to engine bay of
Td5 models.
In addition to the above measures, all steel parts are
zinc-coated both sides.
Underbody Sealer
Underfloor areas and outer sill panels are treated with
a Plastisol PVC underbody sealer. This material is not
suitable for re-treatment.
When repairing areas of underbody sealer, strip the
factory-applied material back to a suitable break point,
ensuring that a clean metal surface is exposed and
that the edge of the existing material adheres soundly
to the panel.
Blanking plugs and grommets in the floor pan (except
those used for wax injection) MUST be fitted before
underbody sealer application. Heat-fusible plugs
which have been disturbed should either be refitted
with the aid of a hot air blower or replaced with rubber
grommets.
NOTE: Application of new underbody
sealer must be carried out between primer
and surfacer paint operations. Areas
where seam sealer is used should be re-treated as
necessary before application of underbody sealer.
CAUTION: Ensure that suspension units,
wheels, tyres, power unit, driveshafts,
exhaust and brakes (including all
mounting points) are shielded prior to application
of fresh underbody sealer.
Cavity Wax
Cavity wax is applied to certain box sctions The
information given on the following pages is intended
as a guide and shows the areas to be treated with
cavity wax, as well as the access holes used during
manufacture.See GENERAL INFORMATION DATA,
Sealing and corrosion protection section.
Underbody Wax
A coat of underbody wax is applied to the entire
underbody inboard of the sill vertical flanges, and
covers all moving and flexible components EXCEPT
for wheels and tyres, brakes and exhaust. The wax is
applied over paints and underbody sealers.
The underbody wax must be reinstated following all
repairs affecting floor panels.
CAUTION: Old underbody wax must be
completely removed from a zone
extending at least 200 mm (7.9 in) beyond
the area where new underbody sealer is to be
applied.
Engine Bay Wax
Reinstate protective engine bay wax disturbed during
repairs using the approved material.
Wheel Arch Wax
Reinstate protective wheel arch wax disturbed during
repairs using the approved material.
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PANEL REPAIRS
9
SEALING AND CORROSION PROTECTION Stone Chip Resistant Paint/Primer
Re-treat all areas protected with factory-applied
anti-chip primer with suitable approved material in
repair.
Inspections during Maintenance Servicing
It is a requirement of the Land Rover Corrosion
Warranty that the vehicle body is checked for
corrosion by an authorised Land Rover dealer at least
once a year, to ensure that the factory-applied
protection remains effective.
Service Job Sheets include the following operations to
check bodywork for corrosion:
With the vehicle on a lift, carry out visual
check of underbody sealer for damage.
With the vehicle lowered, inspect exterior
paintwork for damage and body panels for
corrosion.
NOTE: Wash the vehicle and ensure that it
is free from deposits prior to inspection. It
is part of the owner’s responsibility to
ensure that the vehicle is kept free of
accumulations of mud which could accelerate the
onset of corrosion. The Dealer MUST wash the
vehicle prior to inspection of bodywork if the
customer has offered it in a dirty condition, and
pay special attention to areas where access is
difficult.
NOTE: The checks described above are
intended to be visual only. It is not
intended that the operator should remove
trim panels, finishers, rubbing strips or sound
deadening materials when checking the vehicle
for corrosion and paint damage.
With the vehicle on a lift, and using an inspection or
spot lamp, visually check for the following:
Corrosion damage and damaged
paintwork, condition of underbody sealer
on front and rear lower panels, sills and
wheel arches.
Damage to underbody sealer on main floor
and chassis members. Corrosion in areas
adjacent to suspension mountings and fuel
tank fixings.
NOTE: The presence of small blisters in
PVC underbody sealer is acceptable,
providing they do not expose bare metal.
Special attention must be paid to signs of damage
caused to panels or corrosion material by incorrect
jack positioning.
It is essential to follow the correct jacking and lifting
procedures.See GENERAL INFORMATION DATA,
Information section.
With the vehicle lowered, visually check for evidence
of damage and corrosion on all painted areas, in
particular the following:
Front edge of bonnet.
Visible flanges in engine compartment and
boot.
Lower body and door panels.
Where bodywork damage or evidence of corrosion is
found during inspection, rectify this as soon as is
practicable, both to minimise the extent of the damage
and to ensure the long term effectiveness of the
factory-applied corrosion protection treatment. Where
the cost of rectification work is the owner’s
responsibility, the Dealer must advise the owner and
endorse the relevant documentation accordingly.
Where corrosion has become evident and is
emanating from beneath a removable component
(e.g. trim panel, window glass, seat etc.), remove the
component as required to permit effective rectification.
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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.
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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.
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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.
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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.
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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.
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