2002 LAND ROVER DISCOVERY 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 lance
7Rigid 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.

BODY SEALING MATERIALS
MATERIALS AND APPLICATIONS 77-3-7
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.
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.

BODY SEALING MATERIALS
77-3-8 MATERIALS AND APPLICATIONS

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' post
2Injection 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 member
3RH 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