Defender (1999-2002). Manual — part 118
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77
PANEL 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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77
PANEL 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
18.6
Combination 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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