Defender. Manual - part 283
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.
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 disconnected 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.
PAINT PROCEDURES
Replacement Panels
Service panels are supplied with a cathodic primer coating as part of the panel protection, and in compliance with the
vehicle's Corrosion Warranty where applicable. DO NOT remove this primer before paint refinishing. In the event of
localised surface damage or imperfections, ensure that the minimum of primer is removed during rectification work for
effective repair.
Rectify damage by panel beating or straightening. To remove corrosion or paint runs on outer surfaces, abrade primer
coat in the affected area as necessary using the following procedure:
Clean the panel using a solvent wipe.
Treat exposed areas of metal with an etch phosphate process.
Re-treat the affected area using either a separate acid-etch primer and two-pack surfacer, or an integrated etch
primer/filler.
Bolted Panels
Before fitting bolt-on panels, ensure that all mating and adjacent surfaces on the vehicle and replacement panel are free
from damage and distortion. Rectify if necessary as described in this section, and apply preformed strip sealer where
specified.
Welded Panels
Remove primer from the immediate vicinity of new and existing panel flanges, cleaning to bright metal finish.
On joints to be spot welded, apply weld-through zinc rich primer to joint faces of both flanges. Make spot welds
while primer is still wet or according to the manufacturer's instructions.
Dress accessible weld seams.
Clean panel using solvent wipe.
Treat bare metal with an etch phosphate process.
Re-treat repaired areas.
It is not satisfactory to use weld-through, zinc rich primers in conjunction with MIG welding.
Sectioned Panels
When replacing part or sectioned panels, the basic procedure is the same as for welded panels described above, with the
following variations:
1. Remove primer from both new and existing joint faces, cleaning to a bright metal finish.
2. Where an overlap joint with the existing panel is to be spot welded, apply weld-through, zinc rich primer to both joint
faces and spot weld while the primer is still wet or according to the manufacturer's instructions.
3. MIG weld joints where applicable.
4. Clean the panel with a solvent wipe.
5. Treat bare metal areas using an etch phosphate process.
6. Re-prime affected areas as necessary as for rectifying transit damage. See this section.
7. Treat the inner faces of lap or butt joints with a suitable cavity wax. See Sealing and Corrosion Protection.
Clinch Panels (eg Door skins etc.)
1. Abrade primer on new and existing panel joint faces, and clean using a solvent wipe.
2. Apply metal-to-metal adhesive where applicable.
3. Where joints are to be spot welded, apply suitable weld-through, zinc rich primer to weld areas.
4. Where joints are to be MIG welded, apply zinc rich primer in adjacent areas but leave the welded area untreated.
5. To retain the panel whilst clinching the flanges, tack spot weld or plug weld as appropriate.
6. Clean the panel with a solvent wipe.
7. Treat bare metal areas with a suitable etch phosphate process.
8. Re-prime affected areas as necessary as for rectifying transit damage. See this section.
9.Replacement doors, bonnets and tailgates must be treated with a suitable seam sealer on clinched seams, following
the primer coat.