LAND ROVER DEFENDER 1999 Workshop Manual

77PANEL REPAIRS
16
SEALING AND CORROSION PROTECTION Rear door
M77 2075A
B - B
1
A
B
B
A
222
2
A - A
Section A-A and B-B show application areas of cavity wax for the rear door. Arrows 1 and 2 show the application
holes.
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PANEL REPAIRS
17
SEALING AND CORROSION PROTECTION SEALANTS AND ADHESIVES
Structural Adhesive
Metal-to-metal adhesive is applied to critical joint
areas during factory assembly. The material used is a
high-temperature, heat cured, nitrile phenolic which
serves both to bond two metal surfaces and also to
seal the joint against ingress of dust, water, petrol and
fumes. This material is not suited for service use, and
should be substituted in repair using a suitable
medium strength adhesive.
When separating a joint treated with metal-to-metaladhesive, to avoid distortion it is recommended that
the joint be gently heated until the bond weakens
sufficiently to permit panel separation.
NOTE: DO NOT carry out MIG welding on a
joint area which has been treated with
metal-to-metal adhesive until all traces of
adhesive have been removed.
The following Illustrations show the treatment areas
for Structural Adhesive.
All areas symmetrically opposite to those shown are
also treated.
Body side capping
Structural adhesive applied around body side lower fixing holes
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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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PANEL REPAIRS
19
SEALING AND CORROSION PROTECTION Seam sealing on bulkhead assembly - front view
All areas symmetrically opposite to those shown are also treated.
Seam sealing on bulkhead assembly - rear view
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77PANEL REPAIRS
20
SEALING AND CORROSION PROTECTION Seam sealer on body side assembly
Seam sealer on front door
NOTE: Seam sealer to be wiped after application for cosmetic purposes.
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PANEL REPAIRS
21
SEALING AND CORROSION PROTECTION Seam sealer on rear end assembly
CAUTION: Do not block drain holes when applying seam sealer.
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77PANEL REPAIRS
22
SEALING AND CORROSION PROTECTION Seam sealer on roof assembly
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PANEL REPAIRS
23
SEALING AND CORROSION PROTECTION PUTTY APPLICATION AREAS
The following Illustrations show the treatment areas for Putty application.
All areas symmetrically opposite to those shown are also treated.
Putty location on bulkhead assembly
Putty location on rear end
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77PANEL REPAIRS
24
SEALING AND CORROSION PROTECTION Putty location on underside of vehicle
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PANEL REPAIRS
25
SEALING AND CORROSION PROTECTION Putty location on front door
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