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Defender (1999-2002). Manual - part 119

PANEL REPAIRS

REPAIR

Bodyside combination panel times

Panel description

Total time

Front door
Wheelarch eyebrow
Wing - lower
Wing - upper

15.4 LH
15.5 RH

Front door
Rear door
Sill and ’B’ post

16.6 LH
16.5 RH

Rear door
Body side lower assembly
Body side upper assembly
Wheel arch eyebrow
’D’ post outer reinforcement
Corner capping
Rear lamp panel

31.0 LH
32.1 RH

Rear door
Front door
Wing lower
Wing upper
Body side lower assembly
Body side upper assembly
Wheel arch eyebrow - front & rear
’D’ post outer reinforcement
Corner capping
Rear lamp panel

41.9 LH
42.8 RH

Rear end combination panel times

Panel description

Total time

Corner capping
Rear lamp panel

11.0

Body side lower assembly
Body side upper assembly
Wheel arch eyebrow
’D’ post outer reinforcement
Corner capping
Rear lamp panel
Rear panel

28.9 LH
29.9 RH

Body side lower assembly
Body side upper assembly
Wheel arch eyebrow
’D’ post outer reinforcement
Corner capping
Rear lamp panel
Rear panel

28.5 LH
29.4 RH

PANEL REPAIRS

PAINT

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:

1. Clean the panel using a solvent wipe.
2. Treat exposed areas of metal with an etch

phosphate process.

3. 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

1. Remove primer from the immediate vicinity of

new and existing panel flanges, cleaning to
bright metal finish.

2. 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.

3. Dress accessible weld seams.
4. Clean panel using solvent wipe.
5. Treat bare metal with an etch phosphate

process.

6. Re-treat repaired areas.

NOTE: 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.

PANEL REPAIRS

PAINT

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.

NOTE: Replacement doors, bonnets and
tailgates must be treated with a suitable
seam sealer on clinched seams, following

the primer coat.

Paint Refinishing

1. Seal all accessible exterior and interior seams

with an approved seam sealer. Certain joints
such as sill lower flange seams must be left
unsealed.

2. Apply a suitable anti-chip primer where

specified.

3. Apply a two-pack paint refinishing system.
4. Repair any damage to underbody sealers either

at this stage or before paint operations.

Paint Repairs
Before carrying out paintwork repairs, the vehicle
must be thoroughly cleaned using either a steam
cleaner or high-pressure washer.

Wash locally repaired areas using a mild
water-mixable detergent and wipe them clean with
solvent, immediately prior to paint application.

Abrade damaged paintwork where bare metal has
been exposed until the metal is clean and extends
beyond the area of immediate damage. Treat the bare
metal with an etch phosphate to remove all traces of
rust and provide a key for new paint coats. Re-treat
the affected area using either a separate acid-etch
primer and two-pack surfacer or an integrated etch
primer/filler, and follow with a two-pack paint system.
Those surfaces not receiving paint must be treated
with a cavity wax following paint operations.

M77 2108B

A. Two-pack top coat

B. Two-pack primer filler and etch primer

C. Etch phosphate

82 - AIR CONDITIONING

CONTENTS

Page

ADJUSTMENT

REFRIGERANT RECOVERY, RECYCLING, RECHARGING

.............................

REPAIR

COMPRESSOR

...................................................................................................

MOTOR - CONDENSER FAN

..............................................................................

RECEIVER DRIER

...............................................................................................

RELAY - TEMPERATURE CONTROL - FROM 02MY

.........................................

EVAPORATOR

....................................................................................................

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