service LAND ROVER DEFENDER 1999 Workshop Manual

77PANEL REPAIRS
18
SEALING AND CORROSION PROTECTION Seam Sealers
A heat cured, PVC Plastisol sealer is applied to joint
areas during factory assembly. This material is not
suitable for service use.
Carry out seam sealing after the application of primer
and before the surfacer and final paint coats. Ensure
that surfaces are first cleaned of all grease and oil.
Apply the sealer material to the joint as a bead, either
by hand or using an applicator gun. Where necessary,
brush sealer well into the joint and wipe smooth using
a cloth soaked with solvent such as Shell SBP3. This
will ensure an acceptable cosmetic finish.
Apply sealer to ALL accessible joints following repair
work. Be aware that damage to a vehicle can often
result in deflection to those areas of the body which
are remote from the impact. The sealers in these
areas can therefore be disturbed by subsequent
straightening and repair operations. Check joints in
the vicinity of the area undergoing repair for evidence
of cracked sealer, clean them out as required and
re-treat them with fresh sealer using the following
procedure:
Clean the affected joint or seam and
re-treat any exposed metal areas with a
suitable etch phosphate primer.
Treat affected area with an acid-etch
primer.
Apply appropriate seam sealer as
necessary.
Apply appropriate colour coat (and
underbody sealer as applicable).
Where joints are inaccessible following the
reassembly or fitment of components, ensure that a
paste-type sealer is applied to such joints. Certain
seams also become inaccessible after the completion
of panel repairs. In such instances the paint process
should be carried out and sealers applied before final
assembly.Provided access is adequate, apply the sealer to both
sides of the repair joint. Where access is limited to
one side only (e.g. box sections), inject the affected
box member with cavity wax.
CAUTION: ALWAYS deploy an extractor
unit to remove toxic fumes when using
oxy-acetylene equipment to remove panels
treated with wax and sealers.
The following Illustrations show the treatment areas
for Seam Sealing.
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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.
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PANEL REPAIRS
1
PANELS SERVICEABLE PANELS
Front end panels
1.Bonnet
2.Hinges
3.Bulkhead assembly
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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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AIR CONDITIONING
1
ADJUSTMENT REFRIGERANT RECOVERY, RECYCLING,
RECHARGING
Service repair no - 82.30.02
WARNING: The air conditioning system is
charged with a high pressure, potentially
toxic refrigerant. Repairs or servicing must
only be carried out by an operator familiar with
both the vehicle system and the charging and
testing equipment.
WARNING: All operations must be carried
out in a well ventillated area away from
open flame and heat sources.
WARNING: Wear eye and hand safety
protection.
CAUTION: Overcharging air conditioning
system will cause excessive head
pressure.
An air conditioning portable Refrigerant Recovery
Recycling Recharging Station for use with R134a
refrigerant incorporates all the features necessary to
recover R134a refrigerant from the air conditioning
system; to filter and remove moisture; to evacuate and
recharge with the reclaimed refrigerant. The unit can
also be used for performance testing and air
conditioning system analysis.
The operator must adhere to the equipment
manufacturer’s instructions.
Refrigerant Recovery
1.Remove dust caps from high and low pressure
connectors.
2.Connect high and low pressure hoses to
appropriate connections.
3.Open valves on connectors.
4.Turn valves on refrigerant station to correct
positions.
NOTE: Operate the refrigerant station in
accordance with the manufacturers
instructions.
5.Turn Process switch to correct position.
6.Turn Main switch to’ON’.
7.Allow station to recover refrigerant from system.8.Close valves on refrigerant station.
9.Turn Main switch to’OFF’.
10.Close valves on connectors.
11.Disconnect high and low pressure hoses from
connectors.
12.Fit dust caps to connectors.
13.Open tap at rear of station to drain refrigerant oil
recovered from system.
14.Measure and record quantity of refrigerant oil
recovered from system.
15.Close tap at rear of station.
Evacuation
CAUTION: Whenever the refrigerant
system is opened, the receiver/drier must
be renewed immediately before evacuating
and recharging the system.
1.Remove dust caps from high and low pressure
connectors.
2.Connect high and low pressure hoses to
appropriate connections.
3.Open valves on connectors.
4.Turn valves on refrigerant station to correct
positions.
5.Turn Process switch to correct position.
6.Turn Main switch to’ON’.
7.Allow station to evacuate system.
NOTE: If the vacuum reading is below
700mmHg after 15 minutes, suspect a leak
in the system. Partially recharge the
system and check for leaks using an electronic
leak tester. Check suction lines first, then run the
compressor for 5 minutes. Next check the high
pressure lines.
NOTE: The system must be evacuated
immediately before recharging
commences. Delay between evacuation
and recharging is not permitted.
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AIR CONDITIONING
1
REPAIR COMPRESSOR
Service repair no - 82.10.20
Remove
1.Remove engine acoustic cover.See ENGINE ,
Repair.
2.Depressurise A/C system.See Adjustment.
3.Remove auxiliary drive belt.See
ELECTRICAL, Repair.
4.Drain cooling system.See COOLING
SYSTEM, Adjustment.
5.Disconnect multiplug from compressor.
6.Remove 2 bolts securing air conditioning pipes
to compressor and discard’O’rings.
CAUTION: Immediately cap all air
conditioning pipes to prevent ingress of
dirt and moisture into the system.
7.Release clips and disconnect top hose from
coolant elbow and heater pipe.
8.Remove 4 bolts securing compressor to
mounting bracket.
9.Remove compressor.Refit
10.Position compressor to mounting bracket and
tighten bolts to25 Nm (18 lbf.ft).
11.Remove caps from compressor and pipe
connections.
12.Clean compressor and pipe connections.
13.Lubricate new’O’rings with refrigerant oil and fit
to compressor.
14.Position A/C pipes to compressor and tighten
bolts to9 Nm (7 lbf.ft).
15.Connect multiplug to compressor.
16.Position top hose and secure with clips.
17.Refill cooling system.See COOLING SYSTEM,
Adjustment.
18.Fit auxiliary drive belt.See ELECTRICAL,
Repair.
19.Recharge A/C system.See Adjustment.
20.Fit engine acoustic cover.See ENGINE ,
Repair.
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82AIR CONDITIONING
2
REPAIR MOTOR - CONDENSER FAN
Service repair no - 82.15.01
Remove
1.Remove 6 screws and remove radiator grille.
2.Disconnect fan multiplug and release multiplug
holder from retaining clip.
3.With assistance remove 4 nuts and bolts
securing motor to condenser.
4.Remove motor.
Refit
5.Position motor to condenser and with assistance
tighten nuts and bolts to8 Nm (6 lbf.ft).
6.Connect motor multiplug.
7.Position radiator grille and secure with screws.RECEIVER DRIER
Service repair no - 82.17.03
Remove
1.Recover refrigerant from A/C system.See
Adjustment.
2.Remove 2 bolts securing pipe unions to receiver
drier.
3.Release pipes and discard’O’rings.
CAUTION: Immediately cap all air
conditioning pipes to prevent ingress of
dirt and moisture into the system.
4.Remove 2 bolts securing receiver drier mounting
bracket to chassis.
5.Remove receiver drier, slacken clamp bolt and
remove bracket.
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AIR CONDITIONING
3
REPAIR Refit
6.Position bracket to receiver drier and tighten
clamp bolt.
7.Position receiver to chassis and tighten bolts.
8.Remove plugs from A/C pipes.
9.Lubricate new’O’rings with refrigerent oil.
10.Fit’O’rings, position pipes and tighten bolts to8
Nm (6 lbf.ft).
11.Recharge A/C system.See Adjustment.RELAY - TEMPERATURE CONTROL - FROM 02MY
Service repair no - 82.20.40
Remove
1.Remove front speaker from drivers side.See
ELECTRICAL, Repair.
2.Release relay from support bracket.
3.Disconnect multiplug and remove relay.
Refit
4.Connect multiplug to relay and fit relay to
bracket.
5.Fit front speaker.See ELECTRICAL, Repair.
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82AIR CONDITIONING
4
REPAIR EVAPORATOR
Service repair no - 82.25.20
Remove
1.Remove battery cover.
2.Recover refrigerant from A/C system.See
Adjustment.
3.Remove 2 bolts securing A/C pipes to
evaporator.
4.Release pipes and discard’O’rings.
CAUTION: Immediately cap all air
conditioning pipes to prevent ingress of
dirt and moisture into the system.
5.Remove 2 screws and release fuse/relay bracket
from body and collect 2 spacers.
6.Remove 8 screws securing speakers to A/C
duct.
7.Disconnect speaker Lucars and remove
speakers.
8.Remove 4 screws and bolt securing A/C duct to
fascia panel.
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WIPERS AND WASHERS
1
REPAIR PUMP - WINDSCREEN WASHER
Service repair no - 84.10.21
Remove
1.Remove headlamp.See ELECTRICAL,
Repair.
2.Position drain tin to collect any fluid spillage.
3.Disconnect multiplug from washer pump.
4.Disconnect hose from washer pump.
5.Release washer pump from reservoir and
discard sealing washer.
Refit
6.Fit new sealing washer and secure pump to
reservoir.
7.Connect hose and multiplug to washer pump.
8.Fit headlamp.See ELECTRICAL, Repair.
9.Fill reservoir with screen cleaning fluid.JET - REAR SCREEN WASHER
Service repair no - 84.30.09
Remove
1.Release and remove both rear side window
finishers.
2.Remove 8 screws securing both rear grab
handles.
3.Remove both rear grab handles.
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