1999 LAND ROVER DEFENDER Workshop Manual

77PANEL REPAIRS
4
REPAIR SCREEN APERTURE
Remove
1.Disconnect both battery leads, negative lead
first.
2.Raise side of vehicle.
3.Remove front and centre headlining sections.
4.Remove both’A’post upper trims.
5.Remove front door aperture seals.
6.Release upper front corner of rear door aperture
seal.
7.Remove both wiper arms.See WIPERS AND
WASHERS, Repair.
8.Remove front screen.
9.Remove all roof fixings, back to the’B/C’post.
10.Release sealant securing front edge of roof.
11.Insert wedges into top of both’B/C’posts. This
will allow access for removal of screen aperture.
12.With assistance remove screen aperture.Refit
13.Prepare and clean panel joint faces.
14.Reverse removal procedure. Fit new foam seal
to top edge of aperture.
NOTE: When refitting, ensure screen
aperture is correctly fitted onto location
pins in bulkhead.
15.When applying sealant to top edge of aperture,
the correct colour sealant must be used, see
note below.
NOTE: White roof vehicles use a white
sealant. Coloured roof vehicles use a
black sealant.
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PANEL REPAIRS
5
REPAIR SILL - FRONT
Remove
NOTE: The procedure to replace the rear
sill section is the same as the front.
1.Remove bolts securing sill to body, discard seal.
Refit
NOTE: Front sill
NOTE: Rear sill
2.Prepare and clean panel joint faces. Refit new
seal.
3.Reverse removal procedure.’B/C’&’D’POST
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove rear door and striker.
3.Remove front seat belt reel.See CHASSIS
AND BODY, Repair.
4.Remove front and rear carpets.
5.Remove front seat.
6.Remove rear seat.
7.Remove front, centre and rear sections of
headlining.
NOTE: Assembly is held on with bolts.
Refit
8.Prepare and clean panel joint faces.
9.Reverse removal procedure.
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77PANEL REPAIRS
6
REPAIR CORNER CAPPING
The Corner Capping is not replaced as a single panel.
It is replaced in conjunction with either the Body Side
Lower Panel or Body Side Assembly. The procedure
to replace the Corner Capping is shown in the Body
Side Lower Panel procedure.
BODY SIDE CAPPING
The Body Side Capping is not replaced as a single
panel. It is replaced in conjunction with either the
Body Side Lower Panel or Body Side Assembly. The
procedure to replace the Body Side Capping is shown
in the Body Side Lower Panel procedure.
BODY SIDE REAR - UPPER
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove front, centre and rear sections of
headlining.
3.Release upper edge of front door aperture seal.
4.Release upper edge of rear door aperture seal.
5.Remove fixings from front edge of roof, and
along side being replaced.
6.Release sealant securing front edge of roof.
7.Insert wedges into top of both’B/C’posts. This
will allow access for removal of body side.
8. RH side:Remove tail door.See CHASSIS
AND BODY, Repair.
9.Remove side window.
10.Remove rear sixth light.
11.Remove all bolts securing upper body side.
Refit
12.Prepare and clean panel joint faces.
13.Reverse removal procedure.
NOTE: When refitting, ensure body side
upper is correctly fitted onto location pins.
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PANEL REPAIRS
7
REPAIR BODY SIDE REAR - LOWER - ASSEMBLY
In this procedure the Body Side Capping and the
Corner Capping are also changed.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove body side upper rear.See this
Section.
3.Remove all rear lamps and reflectors.
4. LH side:Remove number plate and lamp.
5. LH side:Remove tail door striker.
6. RH side:Remove fuel filler and grommet.
7.Remove all bolts and rivets securing lower body
side assembly.
Refit
8.Prepare and clean panel joint faces.
9.Reverse removal procedure.
NOTE: When refitting, ensure body side
upper is correctly fitted onto location pins.
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77PANEL REPAIRS
8
REPAIR BODY SIDE REAR - PANEL
Remove
In this procedure the Body Side Capping and the
Corner Capping are also changed.
1.Disconnect both battery leads, negative lead
first.
2.Remove body side upper rear.See this
Section.
3.Remove rear lamp panel.See this Section.
4. LH side:Remove number plate and lamp.
5. LH side:Remove tail door striker.
6. RH side:Remove fuel filler and grommet.
Refit
7.Prepare and clean panel joint faces. Drill holes in
new body side lower panel for riveting. Spacing
of holes, dimension’A’= 100 mm (3.937’). In
conjunction with the rivets apply suitable
adhesive.
8.Prepare and clean panel joint faces.
9.Reverse removal procedure.
NOTE: When refitting, ensure body side
upper is correctly fitted onto location pins.
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PANEL REPAIRS
9
REPAIR REAR LAMP PANEL
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect alternator.
3.Remove rear bench seat.
4. RH side:Remove tail door.See CHASSIS
AND BODY, Repair.
5.Remove rear lights and reflector.
6. LH side:Remove number plate and tail door
striker.
Refit
7.Prepare and clean panel joint faces.
8.Reverse removal procedure.REAR CROSSMEMBER PANEL
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove both rear lamp panels.See this
Section.
Refit
3.Prepare and clean panel joint faces.
4.Reverse removal procedure.
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77PANEL REPAIRS
10
REPAIR ROOF ASSEMBLY
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove rear bench seats.
3.Remove front, centre and rear sections of
headlining.
4.Remove all bolts securing roof.
NOTE: Carefully cut sealant securing front
edge of roof to windscreen aperture.
Refit
5.Prepare and clean panel joint faces.
6.Reverse removal procedure.
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PANEL REPAIRS
11
REPAIR TIME SCHEDULES
The following information shows the total time taken to
replace single panels and complete assemblies. This
time includes removal of Mechanical, Electrical and
Trim (MET) items, plus paint times based on Metallic
Clear Over Base Paint.
The times shown were generated by Thatcham (the
Motor Insurance Repair and Research Centre) and
are to be used as a guide only. The operations were
carried out on a 110 Station Wagon.
Panel/assembly replacement times
Panel Description Total time
Bonnet 6.1
Bulkhead 24.2
Door front - each 7.8
Door rear - each 6.9
Door tail 7.7
Headlamp mounting panel LH 8.4
Headlamp mounting panel RH 8.3
Rear lamp mounting panel 9.3
Front screen aperture 7.4
Roof assembly 18.0
Sill and’B’post assembly LH 9.4
Sill and’B’post assembly RH 9.3
Sill panel - front section 4.2
Sill panel - rear section 4.1
Wing front lower 7.0
Wing front upper 8.7
Body side rear assembly - LH 16.7
Body side rear assembly - RH 17.7
Body side lower panel - LH 17.6
Body side lower panel - RH 18.6Combination panel replacement times
The following panel combination times show the total
time to remove/refit body panels, MET items and any
paint processes.
Front end combination panel times
Panel Description Total Time
Grille
Bumper front
Wheelarch eyebrow
Wing - upper
Wing - lower
12.7 LH
12.6 RH
Grille
Bumper front
Wheelarch eyebrow LH & RH
Wing - upper LH & RH
Wing - lower LH & RH
18.2
Grille
Bumper front
Wheelarch eyebrow
Wheelarch front
Wing - upper
Wing - lower
13.1 LH
13.0 RH
Grille
Bumper front
Wheelarch eyebrow LH & RH
Wheelarch front LH & RH
Wing - upper LH & RH
Wing - lower LH & RH
19.0
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