1999 LAND ROVER DEFENDER Workshop Manual

76CHASSIS AND BODY
36
REPAIR LOWER FASCIA PANEL - FROM 02MY
Service repair no - 76.46.05
Service repair no - 80.10.12
NOTE: This procedure also covers
removal of the air distribution control
cable, 80.10.12.
Remove
1.Disconnect battery negative lead.See
ELECTRICAL, Repair.
2.Remove steering column nacelle.See
STEERING, Repair.
3.Remove fascia console.See this Section.
4.Remove air vent control knobs.
5.Remove 6 screws, remove fascia closing panel
and collect nut plate.
6.Remove speakers.See ELECTRICAL, Repair.
7.Remove 2 screws and remove both door check
strap covers.
8.Remove 3 screws and remove end cap from
lower fascia panel.
9.Loosen grub screw and clamp plate bolt
securing air distribution cable. Release cable
from control lever.
10.Release screen demister tubes from lower fascia
panel.
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CHASSIS AND BODY
37
REPAIR
11.Remove 2 screws securing fuse cover and
remove cover.
12.Remove 7 screws securing lower edge of fascia
panel.
13.Remove footwell cover retaining plates.
14.Remove 2 nuts and remove lower fascia panel.
NOTE: Do not carry out further
dismantling if component is removed for
access only.
15.Remove 21 screws and release air duct cover.
16.Loosen trunnion screw, remove air distribution
cable and duct cover.Refit
17.Fit air distribution cable to duct cover and fit
inner cable to vent flap trunnion.
18.Tighten vent flap trunnion screw to6Nm(4
lbf.ft)and bend cable end to secure.
19.Fit duct cover to lower fascia and fit and tighten
screws.
20.Check condition of seal between heater and
lower fascia, if damaged replace.
21.Carefully fit lower fascia panel and ensure
harness route is correct.
22.Secure lower fascia panel with screws and
tighten nuts to10 Nm (7 lbf.ft).
23.Fit fuse cover and secure with screws.
24.Connect demister tubes to lower fascia panel.
25.Raise air distribution lever to screen demist
position and close footwell vent.
26.Connect air distribution cable to lever, tighten
grub screw and outer cable clamp.
27.Fit end cap to fascia and secure with screws.
28.Fit check strap covers and secure with screws.
29.Fit speakers.See ELECTRICAL, Repair.
30.Fit fascia closing panel.
31.Fit nut plate and fit screws to secure nut plate
and closing panel.
32.Fit knobs to air vent control levers.
33.Fit fascia console.See this Section.
34.Fit steering column nacelle.See STEERING,
Repair.
35.Connect battery negative lead.See
ELECTRICAL, Repair.
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76CHASSIS AND BODY
38
REPAIR
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77 - PANEL REPAIRS
CONTENTS
Page
INFORMATION
BODY REPAIRS 1..................................................................................................
ELECTRONIC CONTROL UNITS (ECU’s) 3..........................................................
BODY DIMENSIONS
CHASSIS AND BODY 1..........................................................................................
CHASSIS FRAME ALIGNMENT 2..........................................................................
GAP AND PROFILE INFORMATION 9...................................................................
SEALING AND CORROSION PROTECTION
APPROVED MATERIALS 1....................................................................................
APPLICATION EQUIPMENT 4...............................................................................
CORROSION PROTECTION 8...............................................................................
CAVITY WAX 12.....................................................................................................
SEALANTS AND ADHESIVES 17..........................................................................
WATER LEAKS 28..................................................................................................
PANELS
SERVICEABLE PANELS 1.....................................................................................
PROCEDURES
GENERAL WELDING PRECAUTIONS 1...............................................................
PANEL REPLACEMENT PROCEDURE 2..............................................................
REPAIR PROCEDURES 6......................................................................................
REPAIR
WING LOWER FRONT 1........................................................................................
HEADLAMP MOUNTING PANEL 1........................................................................
WING UPPER - LH 2..............................................................................................
WING UPPER - RH 2..............................................................................................
WHEEL ARCH - FRONT 3......................................................................................
BULKHEAD ASSEMBLY 3......................................................................................
SCREEN APERTURE 4..........................................................................................
SILL - FRONT 5......................................................................................................
’B/C’&’D’POST 5..................................................................................................
CORNER CAPPING 6.............................................................................................
BODY SIDE CAPPING 6.........................................................................................
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77 - PANEL REPAIRS
CONTENTS
Page
BODY SIDE REAR - UPPER 6...............................................................................
BODY SIDE REAR - LOWER - ASSEMBLY 7........................................................
BODY SIDE REAR - PANEL 8................................................................................
REAR LAMP PANEL 9............................................................................................
REAR CROSSMEMBER PANEL 9.........................................................................
ROOF ASSEMBLY 10............................................................................................
TIME SCHEDULES 11............................................................................................
PAINT
PAINT PROCEDURES 1........................................................................................
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PANEL REPAIRS
1
INFORMATION BODY REPAIRS
Body shells are of riveted, bolted and welded
construction and are bolted to the chassis frame.
It is essential that design dimensions and strength are
restored in accident rectification. It is important that
neither structural weakness nor excessive local
stiffness are introduced into the vehicle during body or
chassis repair.
Repairs usually involve a combination of operations
ranging from straightening procedures to renewal of
either individual panels or panel assemblies. The
repairer will determine the repair method and this
decision will take into account a balance of economics
between labour and material costs and the availability
of repair facilities in both equipment and skills. It may
also involve considerations of vehicles down-time,
replacement vehicle availability and repair turn-around
time.
It is expected that a repairer will select the best and
most economic repair method possible, making use of
the facilities available. The instructions given are
intended to assist a skilled body repairer by expanding
approved procedures for panel replacement with the
objective of restoring the vehicle to a safe running
condition and effecting a repair which is visually
acceptable and which, even to the experienced eye,
does not advertise the fact that it has been damaged.
This does not necessarily mean that the repaired
vehicle will be identical in all respects with original
factory build. Repair facilities cannot always duplicate
methods of construction used during production.
The panel repairs shown in this section are all based
on a 110 Station Wagon. Therefore all illustrations
and text relate only to this model. Although certain
areas of the vehicle, such as the front end, are
relevant to all models.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and suspension
geometry checked after completion and if necessary a
road test of the vehicle is carried out, particularly
where safety related items are concerned.Where major units have been disconnected or
removed, it is necessary to ensure that fluid levels are
checked and topped up when necessary. It is also
necessary to ensure that the repaired vehicle is in a
roadworthy condition in respect of tyre pressures,
lights, washer fluid etc.
Body repairs often involve the removal of mechanical
and electrical units as well as associated wiring.
Where this is necessary use the relevant section in
this manual.
Taking into consideration the differences in body
styles, steering and suspension systems as well as
engine and suspension layouts, the location of the
following components as applicable to a particular
vehicle is critical:
Front suspension upper damper
mountings.
Front suspension or sub frame mountings.
Engine mountings on RH and LH chassis
longitudinals.
Rear suspension upper damper mountings.
Rear suspension mountings or lower
pivots.
Steering rack mountings.
Additional points which can be used to check
alignment and assembly are:
Inner holes in crossmember - side - main
floor.
Holes in valance front assembly.
Body to chassis mounting holes.
Holes in rear floor.
Holes in rear lower panels or extension
rear floor.
Fuel tank mountings.
Apertures for windscreen, backlight, bonnet and doors
can be checked by offering up an undamaged
component as a gauge and also by measuring known
dimensions.See BODY DIMENSIONS section.
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77PANEL REPAIRS
2
INFORMATION Straightening
Whenever possible, chassis structural members
should be cold straightened under tension. Do not
attempt to straighten with a single pull, but rework the
damaged area using a series of pulls, releasing
tension between each stage and using the opportunity
to check alignment.
Body jig
Unless damage is limited to cosmetic panels, all repair
work to body members must be carried out on a body
jig, to ensure that impact damage has not spread into
more remote parts of the body structure. Mounting on
a jig will also ensure that the straightening and panel
replacement procedures do not cause further
distortion. If original dimensions cannot be
satisfactorily restored by these methods, damaged
structural members should be replaced. Damaged
areas should be cut away using a high speed saw,
NOT an oxy-acetylene torch.
As a rule, body dimensions are symmetrical about the
centre line. A good initial check for distortion is
therefore to measure diagonally and to investigate
apparent differences in dimensions.Inspection
Every accident produces individual differences in
damage. Each repair is influenced by the extent of the
damage and by the facilities and equipment available
for its rectification.
Most accident damage can be visually inspected and
the approximate extent of the damage assessed.
Sometimes deformation will extend beyond the area
of direct damage, and the severity of this must be
accurately established so that steps may be taken to
restore critical body components to their original
dimensions.
An initial check of critical dimensions can be carried
out by means of drop checks or (preferably) trammels.
Gauges are available which will check accurately for
body twist. Where repairs necessitate renewal of a
critical body component it is recommended that a
body jig is used.
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PANEL REPAIRS
3
INFORMATION ELECTRONIC CONTROL UNITS (ECU’s)
The ECU’s fitted to Defender vehicles make it
advisable to follow suitable precautions prior to
carrying out welding repair operations. All ECU’s must
be diconnected before any welding operations take
place. Harsh conditions of heat and vibration may be
generated during these operations which could cause
damage to the units.See ELECTRICAL
PRECAUTIONS section.
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