1999 LAND ROVER DEFENDER Workshop Manual

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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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BODY DIMENSIONS GAP AND PROFILE INFORMATION
The following information is to be used as a guide to assist the technician in refitting exterior body panels and trim
items, to achieve a correctly aligned and cosmetically acceptable vehicle.
Section A-A, Bonnet to wing, gap A = 3 - 8 mm. To be parallel within 2 mm.
Section B-B, Wing to’A’post lower, gap B = 0. Profile = +/- 1 mm.
Section C-C, Wing to sill, gap C = 0. Profile = +/- 1 mm.
Section D-D, Screen aperture to door frame, gap D = 5 - 9 mm.
Section E-E, Door frame to roof, gap E = 7 - 11 mm.
Section F-F, Front and rear door to’B/C’post, gap F = 7 - 11 mm.
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BODY DIMENSIONS
Section G-G, Door to sill, gap G = 7 - 11 mm. Door profile to sill = 0 to + 2 mm.
Section H-H, Rear door to body, gap H = 7 - 11 mm. Door profile to body = 0 to + 3 mm.
Section J-J, Body side lower to body, gap J = 0 - 4 mm. To be parallel within 2 mm.
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BODY DIMENSIONS
Section K-K, Roof to taildoor, gap K = 7 - 9 mm. Profile = +/- 1 mm.
Section L-L, N-N, Body side to taildoor, gap L = 5 - 7 mm. Profile = +/- 1 mm.
Section M-M, Body rear to taildoor, gap M = 7 - 9 mm.
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BODY DIMENSIONS
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SEALING AND CORROSION PROTECTION APPROVED MATERIALS
Joint types:
1. Between bolted panels
2. Between bolted panel edges
3. Between spot welded panels
4. Between spot welded panel edges
5. Between bonded panels
6. Between bonded panel edges7. Clinch joints (type a)
8. Clinch joints (type b)
9. Clinch joints (type c)
10. Gaps between panels (type a)
11. Gaps between panels (type b)
12. Lap joint
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SEALING AND CORROSION PROTECTION DESCRIPTION - USEAGE SUPPLIER PART NUMBER
CAVITY WAXES
Inner Cavity Wax (Transparent) 3M (08909, 08919,
08929)
Inner Cavity Wax (Amber) 3M (08901, 08911,
08921)
Cavity Wax Croda (PW57)
ENGINE BAY WAXES/LACQUERS
Astrolan engine bay wax and Cosmetic Wax Astors DA3243/1
Engine Bay Cosmetic Wax/Lacquer Croda PW197
Engine Bay Cosmetic Wax/Lacquer Dinol 4010
MISCELLANEOUS MATERIALS
Flexible Parts Repair Material - rubber modified
polypropylene parts3M: (05900)
Aerosol Auto’Adhesive (trim) - impact adhesive for trim parts 3M (08080)
Water Shedder Repair Teroson:
Sound dampening foam Gurit Essex: Betacore 7999
SEAM SEALERS
Body Caulking - type (b) gaps between panels 3M 08568
Drip Chek Clear - bolted, spot welded and bonded panel
edges; type (a) and (b), gaps between panels; type (c) clinch
joints3M 08401
Drip Chek Heavy - type (b) gaps between panels; type (c)
clinch joints3M 08531
Flexseal Polyurethane Seam Sealer - bolted, spot welded
and bonded panel edges; type (a) and (b) gaps between
panels; type (b) clinch joints3M (08684, 08689,
08694)
Polyurethane Sealer (sachet) 3M (08703, 08783,
08788)
Sprayable Sealer - type 12 lap joints 3M (08800, 08823)
Super Seam Sealer - type 12 lap joints 3M (08537)
Weld Thru’Sealer - between spot welded panels 3M (08625)
Betafill Clinch and Brushable Sealer (Black, Grey, White) Gurit Essex 10211/15/20
Clinch Joint and Underbody Coating (Grey, Beige) Gurit Essex (10101, 10707)
Leak-Chek Clear - between bolted panels; spot welded and
bonded panel edges; type (c) clinch jointsKent Industries (10075)
Putty - type (a) and (b) gaps between panels Kent Industries
Polyurethane Seam Sealer between bolted panels; spot
welded and bonded panel edges; type (a) and (b) gaps
between panelsPPG (6500)
Polyurethane Seam Sealer between bolted panels; spot
welded and bonded panel edges; type (a) and (b) gaps
between panelsTeroson 92
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SEALING AND CORROSION PROTECTION DESCRIPTION - USEAGE SUPPLIER PART NUMBER
SEAM SEALERS - continued
Terolan Light Seam Sealer - bolted, spot welded and bonded
panel edges; type (a) and (b) gaps between panels; between
bonded panels; type (c) clinch jointsTeroson
Terolan Special Brushable Seam Sealer - lap joints 12 Teroson
Terostat Sprayable Seam Sealer - bolted, spot welded and
bonded panel edges; between bonded panels; type (a) and
(b) gaps between panelsTeroson 9320
Terostat 1K PU Seam Sealer (SE 20) - type (a) and (b) gaps
between panels; spot welded and bonded panel edgesTeroson
Sealing compound - bolted, spot welded and bonded panel
edges; type (b) gaps between panelsWurths 8901001/-/6
STRUCTURAL ADHESIVES
Automotive Structural Adhesive - between bonded panels;
type 5 and 73M 08122
Two part Structural Epoxy - between bonded and spot
welded panels; type (a) clinch jointsCiba - Geigy XB5106/7
UNDERBODY SEALERS
Body Schutz 3M 08861
Spray Schutz 3M 08877
Crodapol Brushable Sealer Croda PV75
Terotex Underseal (CP02) Teroson 9320
UNDERBODY WAXES
Stone chip coating (smooth) 3M 08158/9
Underbody Wax Croda PW61
Underbody Wax Dinol Tectacote 205
WELD-THROUGH PRIMERS
Weld-thru’coating 3M 05913
Zinc Spray 3M 09113
Zinc Rich Primer ICI P-565 634
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