LAND ROVER DISCOVERY 1999 Workshop Manual

BODY SEALING MATERIALS
77-3-6 MATERIALS AND APPLICATIONS
Cavity wax application equipment and techniques
1Air inlet
2Flow control (spray pattern adjustment)
3Pressure cup (1 litre capacity). Maximum
pressure 140PSI (9.7 bar, 9.84 kg/cm
3)
4Gun connector
5Lance nipple connection
6Flexible lance7Rigid directional hook wand
(forward cone spray pattern)
8Flexible nylon lance 1100 mm (43.307 in) with
360° spray pattern
9Rigid lance 1100 mm (43.307 in) with 360°
spray pattern
When re-treating wax-injected areas which have been disturbed during repairs, it is necessary to use a compressed
air spray gun with integral pressure cup and a selection of interchangeable lances.
The following points must be observed during use, according to the attachments fitted:
lUse the rigid or flexible lance attachments with 360° spray dispersal when treating enclosed areas, to ensure
maximum coverage;
lWhere openings are restricted, use the hook nozzle to provide a more directional spray (e.g. inside narrow or
short box sections);
lSpray exposed underbody surfaces directly from the gun less lance attachment and without disconnecting the
fluid coupling.
1100 mm (43.307 in) rigid lance
The nozzle on the rigid lance produces a 360° circular spray pattern combined with a forward-directed spray. Although
wax is distributed to all box section surfaces in a single stroke, effective and complete coverage is obtained in long
straight structures and box section cavities by spraying on both inward and outward strokes of the lance.
The rigid lance also provides the positional accuracy required in shaped sections, by allowing visual assessment.
CAUTION: Do not force the lance into access holes when using this attachment.
1100 mm (43.307 in) flexible nylon lance
This lance is similar in pattern to the rigid version, but provides the additional penetration required for curved sections
or in places where access is difficult. Its main limitation is a lack of positional accuracy inside box sections.
Carry out all spraying on the outward stroke of the lance. Withdraw the lance slowly to ensure sufficient coverage. Do
not withdraw the lance too quickly.
Ensure that the nylon tube of the lance is kept away from the edges of the access hole to eliminate abrasion and
extend the life of the tube. Take care to ensure that spraying ceases just before the nozzle emerges from the access
hole. To assist in this process paint the final 30 mm (1.181 in) of the nozzle with RED paint.

BODY SEALING MATERIALS
MATERIALS AND APPLICATIONS 77-3-7
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 treating short, narrow sections, and
may also be used for direct spraying of inner wheel arches etc.
In use, 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 as required, to ensure full coverage.
NOTE: Always clean gun after use with appropriate solvent to maintain efficiency.

CORROSION PREVENTION AND SEALING
CORROSION PREVENTION 77-4-1
CORROSION PREVE NTION AND SEALING CORROSION PREVE NTION
Cavity wax treatment areas and injection
holes - 'A' post and sill
All areas symmetrically opposite to those shown are also treated.
1Injection hole for 'A' post2Injection hole for sill
1
C-C C
C
M77 1671A 2
B-B
B
B

CORROSION PREVENTION AND SEALING
77-4-2 CORROSION PREVENTION
Cavity wax treatment area and injection
hole - fuel filler neck
1Injection hole for fuel filler neck

CORROSION PREVENTION AND SEALING
CORROSION PREVENTION 77-4-3
Cavity wax treatment areas and injection
holes - rear cross member
1LH Injection hole for rear cross member
2Top injection hole for rear cross member3RH Injection hole for rear cross member

CORROSION PREVENTION AND SEALING
77-4-4 CORROSION PREVENTION
Cavity wax treatment areas and injection
holes - front door, rear door and tail door
All areas symmetrically opposite to those shown are also treated.

CORROSION PREVENTION AND SEALING
CORROSION PREVENTION 77-4-5
1Injection holes for tail door
2Injection holes for front door
3Injection hole for rear door

CORROSION PREVENTION AND SEALING
77-4-6 CORROSION PREVENTION
Corrosion prevention
Factory treatments
During production, vehicle bodies are treated with the following anti-corrosion materials:
lA PVC-based underbody sealer which is sprayed onto the underside of the main floor, rear floor, front and rear
wheelarches and the front valance assembly;
lAn application of cavity wax which is sprayed into the sill panels, 'A' post, 'B-C' post, fuel filler aperture, body rear
panel and the lower areas of the door panels;
lA coating of underbody wax which is applied to the entire underbody inboard of the sill vertical flanges, and
covers all moving and flexible components EXCEPT for wheels, tyres, brakes and exhaust;
lA coat of protective wax applied to the engine bay area.
Whenever body repairs are carried out, ensure the anti-corrosion materials in the affected area are repaired or
renewed as necessary using the approved materials.

+ BODY SEALING MATERIALS, MATERIALS AND APPLICATIONS, Approved materials.
Precautions during body repairs and handling
Take care when handling the vehicle in the workshop. Underbody sealers, seam sealers, underbody wax and body
panels may be damaged if the vehicle is carelessly lifted.

+ LIFTING AND TOWING, LIFTING.
Proprietary anti-corrosion treatments
The application of proprietary anti-corrosion treatments, in addition to the factory-applied treatment, could invalidate
the Corrosion Warranty and should be discouraged. This does not apply to Rover approved, compatible, preservative
waxes which may be applied on top of existing coatings.
Fitting approved accessories
When fitting accessories ensure that the vehicle's corrosion protection is not affected, either by breaking the protective
coating or by introducing a moisture trap.
Do not screw self-tapping screws directly into body panels. Fit suitable plastic inserts to the panel beforehand. Always
ensure that the edges of holes drilled into panels, chassis members and other body parts are protected with a suitable
zinc rich or acid etch primer, and follow with a protective wax coating brushed onto the surrounding area.
Do not attach painted metal surfaces of any accessory directly to the vehicle's bodywork unless suitably protected.
Where metal faces are bolted together always interpose a suitable interface material such as weldable zinc rich
primer, extruded strip, or zinc tape.
Steam cleaning and dewaxing
Due to the high temperatures generated by steam cleaning equipment, there is a risk that certain trim components
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 300 mm (11.811 in) 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.
Inspections during maintenance servicing
It is a requirement of the 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:
lWith the vehicle on a lift, carry out visual check of underbody sealer for damage;
lWith the vehicle lowered, inspect exterior paintwork for damage and body panels for corrosion.
It will be necessary for the vehicle to be washed by the Dealer prior to inspection of bodywork if the customer has
offered the vehicle in a dirty condition.

CORROSION PREVENTION AND SEALING
CORROSION PREVENTION 77-4-7
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:
lCorrosion damage and damaged paintwork, condition of underbody sealer on front and rear lower panels, sills
and wheel arches;
lDamage to underbody sealer. Corrosion in areas adjacent to suspension mountings and fuel tank fixings.
NOTE: The presence of small blisters in the underbody sealer is acceptable, providing they do not expose bare metal.
Pay special attention to signs of damage caused to panels or corrosion protection material by incorrect jack
positioning.
WARNING: It is essential to follow the correct jacking and lifting procedures.
With the vehicle lowered, visually check for evidence of damage and corrosion on all visible painted areas, in
particular the following:
lFront edge of bonnet;
lVisible flanges in engine compartment;
lLower body and door panels.
Rectify any bodywork damage or evidence of corrosion found during inspection 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
prevention 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.
Underbody protection repairs
Whenever body repairs are carried out, ensure that full sealing and corrosion protection treatments are reinstated.
This applies both to the damaged areas and also to areas where protection has been indirectly impaired, as a result
either of accident damage or repair operations.
Remove corrosion protection from the damaged area before straightening or panel beating. This applies in particular
to panels coated with wax, PVC underbody sealer, sound deadening pads etc.
WARNING: DO NOT use oxy-acetylene gas equipment to remove corrosion prevention materials. Large
volumes of fumes and gases are liberated by these materials when they burn.
NOTE: Equipment for the removal of tough anti-corrosion sealers offers varying degrees of speed and effectiveness.
The compressed air-operated scraper (NOT an air chisel) offers a relatively quiet mechanical method using an
extremely rapid reciprocating action. Move the operating end of the tool along the work surface to remove the material.
The most common method of removal is by means of a hot air blower with integral scraper.
Another tool, and one of the most efficient methods, is the rapid-cutting 'hot knife'. This tool uses a wide blade and is
quick and versatile, able to be used easily in profiled sections where access is otherwise difficult.
Use the following procedure when repairing underbody coatings:
1Remove existing underbody coatings
2After panel repair, clean the affected area with a solvent wipe, and treat bare metal with an etch phosphate
material
3Re-prime the affected area
CAUTION: DO NOT, under any circumstances, apply underbody sealer directly to bare metal surfaces.
4Replace all heat-fusible plugs which have been disturbed. Where such plugs are not available use rubber
grommets of equivalent size, ensuring that they are embedded in sealer
5Mask off all mounting faces from which mechanical components, hoses and pipe clips, have been removed.
Underbody sealer must be applied before such components are refitted
6Brush sealer into all exposed seams
7Spray the affected area with an approved service underbody sealer
8Remove masking from component mounting faces, and touch-in where necessary. Allow adequate drying time
before applying underbody wax