Part 2
Removal
The ESN50 is the approved removal tool for Self Piercing Fixings. The ESN50 can be used with an optional, larger, 200mm C frame for improved access. Where tool access is impossible, drill out the remnant using a 5.3mm Cryobit drill bit. Remove all debris.
Installation
The ESN50 is the approved installation tool for Self Piercing Fixings. Where the original panel is being refitted, the new fixings should be placed adjacent to the original. Only where the ESN50 cannot be used, or there is insufficient space on the panel, should the fixings be replaced with Breakstem Fastener Type As, unless the repair method dictates otherwise.
Using the ESN50
Make sure there is access for the ESN50 on both sides of the fixing to be removed/installed, including the optional C frame if required.
Removal: Align the plunger and anvil over the fixing and depress the trigger. Depressing the trigger will allow the plunger to act on the fixing and remove it from the panel.
NOTE: Prior to replacing a self-piercing fixing, a test, using identical materials from waste panels, should be performed, to make sure that all settings are correct and an acceptable joint has been achieved.
Installation: Load new fixing into ESN50. Align the ESN50 over the fixing position and depress the trigger. As the trigger is depressed the ESN50 will clamp itself onto the work piece and install the fixing.
Removal of service SPR
Service SPR's will require the service anvil to have an internal diameter of 9mm, as shown in graphic E152490.
BREAKSTEM FASTENERS
Breakstem Fasteners are used in repair if the joint/stack cannot be accessed from both sides or require a greater load.
- Breakstem fasteners will cope with joint/stack sizes of 1.5mm to 10.8mm.
- A pre-drilled 6.5mm hole will be required before fitment.
- To identify the correct size and part number of structural breakstem fasteners to be used in repair always refer to TOPlx.
Where original rivet holes cannot be used replacement rivets should be positioned close to the original rivet location/hole location.
When riveting, the first location of the first replacement panel is close to the original rivet placement, not in the centre. The same process is followed by the next replacement, again not in the centre between the rivets.
Breakstem Fastener
Breakstem Fasteners have the following benefits:
- Exceptional shear and tensile strength
- Large blind side bearing area against the rear sheet
- Interference lock formed by a splined stem
- Spreads the tail bearing/clamp load on the rear sheet
- Provides strong, vibration resistant joints
- No loose stems
When the repair procedure requires the fitment of a breakstem fastener the stack size is identified within the repair procedures (millimetres). The table below identifies the correct breakstem fastener to the stack size.
Removal
Breakstem Fastener used in production are removed by removing the centre of the fixing using a 4mm punch. Once the centre has been removed, drill out the remnant using a 6.5mm Cryobit drill bit. Remove all debris. Aftermarket Breakstem Fastener are removed in the same way as Breakstem Fastener used in production.
Installation
The Genesis G4 is the approved installation tool for Breakstem Fastener. Prior to replacement make sure the fixing hole has been drilled to 6.5mm, using a Cryobit drill bit and all debris has been removed.
Using the Genesis G4
Make sure the fixing hole has been drilled to 6.5mm and all debris has been removed. Check that you have the correct size Breakstem Fastener for replacement and insert it into the Genesis G4. Use the weight of the Genesis G4 to apply light pressure as the Breakstem Fastener is inserted into its hole. Depress the trigger which will tighten the Breakstem Fastener in the hole, the wasted stud will be ejected into the Genesis G4 once a pre-determined pressure is reached.
Torx Screw and Rivnut
A Torx Screw and Rivnut are used where the fitment of a Breakstem Fastener Type A would give a poor cosmetic appearance. There are also occasions where the Torx Screw and Rivnut replaces a Breakstem Fastener Type B, where there is no access for the Genesis G4. The Rivnut acts as the thread.
Removal
The removal of the Torx Screw is carried out using a T30 Torx Driver. The Rivnut is not an original fixing.
Installation
The Torx Screw is installed using a T30 Torx Driver. The Rivnut is installed using the Wurth HES412 Rivet Nut Thread Setter, (Part No: 964948900).
aluminum Welding
Health and Safety
Refer to Land Rover Global Tools and Equipment Standards and Equipment Manufactures Manual.
Set Up/Equipment Check
Refer to equipment manufacturers operators' manual.
Weld Process
This section provides information on aftermarket aluminum welding for the all new L405 aluminum range. It covers the following areas:
- Equipment: Metal Inert Gas (MIG)
- Materials: Extruded and pressed aluminum sheet alloy.
- Weld Structure: Fusion welding process: Metal Inert Gas (MIG).
- Weld Procedures: Pre-weld, test weld, weld and post weld checks.
- Weld Variants: Lap weld, Butt weld, Plug weld.
Equipment
NOTE: The Global Body Centre Standards have been published on the HUB, along with the personal protective equipment requirements, at the following locations:
- https://jaguarhub.hub.tagworldwide.com/index.cfm?brand=42701
- https://landroverhub.hub.tagworldwide.com/index.cfm?brand=42701
Only equipment that meets or exceeds the minimum welder standard in the Global Body Centre Tools and Equipment standards should be used in the repair of Land Rover products.
The accuracy of the approved equipment enables the delivery of one droplet of wire per pulse. This enables welding of incredibly thin parent material, i.e. 0.6mm sheet can be welded using a 1.2mm filler wire.
The approved MIG welder uses Direct Current, (DC) and does not produce High Frequency, (HF), at start up, (initial arc).
Welder Set Up
NOTE: The user should always refer to the operators' manual for detailed instructions.
The following provides an overview of the set-up procedure:
- Health and Safety - read operators' manual
- Check correct power supply
- Check gas supply
- Check all equipment parts - safety check
- Attach power cables, connect to supply
- Purge gas bottle, attach
- Attach clamp
Approved equipment obtained from the Land Rover Equipment Program :
- Speedglass with Adflo face shield/weld mask
- Approved fume extractor
- Stainless Steel Brush
- Personal Protection Equipment (PPE)
Materials
Prior to any welding activity, it is necessary to identify the type of material to be welded. The all new L405 aluminum range is constructed from a number of aluminum alloys, each has different attributes that should be considered prior to the weld process.
Body Materials
The repair methods shown focus on the replacement of:
- Pressed aluminum Alloy sheet - 6xxx series - Used in skin-panels
- Extruded aluminum Alloy - 5754 - Used in structural panels
Weld Wire
The approved weld wires for these alloys are:
- 6xxx series - 4043 or 4047 filler wire
- 5754 - 5554 filler wire
Weld Structure
The approved aftermarkets weld process is based on Fusion Welding:
- Metal Inert Gas (MIG) Welding
The approved MIG welder uses DC (direct current). The Electrode, (filler wire), is Positive Pole and the work piece is Negative Pole. The arc burns between a melting electrode, (which also acts as the filler wire) and the work piece. The shielding gas is Argon, Helium or a mixture of these, (MIG).
Successful aluminum welding is partly dependent on the removal of surface Oxidization. Oxide MUST be removed prior to welding. The oxide melts at a different temperature:
- aluminum melting temperature - approximately 660°C
- aluminum Oxide melting temperature - approximately 2040°C
Weld Procedures
Pre-Weld
Prior to starting any weld procedure, the following safety precautions should always be implemented:
- Disconnect the vehicle battery
- Disconnect the generator electrical connectors
- Remove any ECM (engine control module)'s within 500mm of the weld area
- Remove the battery before carrying out welding work in its vicinity
- Utmost care must be taken when welding near the fuel tank or other components that contain fuel. If the tank filler neck or a fuel line must be detached to allow access for welding work, then the fuel tank must be drained and removed
- Adjacent vehicle parts and adjacent vehicles must be shielded against flying sparks and heat
The aluminum surfaces MUST be cleaned prior to welding. Cleaning will aid penetration and avoid contamination. There are three steps to this process:
1. Clean surface:
To remove wax and any other contaminants use a chemical surface cleaner:
- Land Rover approved product: DuPont 3608S
- Alternatively, an Isopropyl based product
2. Remove Oxide
This can be achieved through a number of processes:
NOTE: Items used to remove oxide should not be contaminated by use on a steel vehicle.
- Stainless Steel brush
- 80 Grit abrasive paper
- Non-Metallic scuff pad
3. Remove Oxide Dust
- Remove dust with a lint free cloth
NOTE: Oxide builds up very quickly, therefore, perform steps 2 and 3 immediately prior to welding. If left for a period of time, steps 2 and 3 should be repeated.
Materials
The materials listed in this section are those approved to be used on the all new L405 aluminum range in conjunction with the repairs shown.
Approved Materials
Weld Variants
The following identifies the three types of weld variants used in Category A panel replacement. It is not a guide to welding, as all Category A repairers will have staff who have attended and completed the Jaguar Land Rover aluminum welding accreditation.
This section highlights the key points for each weld variant.
Lap Weld
Key points:
- Run-In/Out distance of 5mm
- Minimum overall length of 20mm
- Must use Start/Finish weld tabs Butt Weld
Butt Weld
Key points:
- Run-In/Out distance of 5mm
- Minimum overall length of 20mm
- Must use Start/Finish weld tabs
- Backing plate required
Plug Weld
Key Points:
- Hole size 10mm
- Position of MIG nozzle - vertical
Backing Plates
Backing plates are required for all butt-weld joints. Backing plate fabrication is made from waste material and have a width of 50mm. Securing backing plates is by either an interference fit, lap-weld, plug-weld or self-tapping screws. Backing plate thickness is determined by work piece thickness, for example; (3mm work piece will require a 3mm backing plate). Backing plates are used to avoid excess penetration, dissipate the heat and supports the molten weld pool while cooling.
Weld Tabs
Weld tabs are manufactured from waste material and placed at the start and end of the effective weld length.
Test Weld
A test weld using identical coupons from waste panels should take place prior to working on the vehicle. The test piece is then visually checked and destructively tested to make sure all settings are correct and an acceptable weld has been achieved.
Prior to starting, the following should be checked:
- Gas - Correct for the type of job
- Filler Wire - Correct for the type of material to be welded
An effective weld should demonstrate the following qualities:
- All visible weld surfaces shall be clean, bright and of a uniform profile
- The weld seam should show uniform height and width over its entire length
- There shall be complete fusion between the surfaces of the work piece and the weld metal deposit
Correct level of penetration will be visible at the rear of the coupon as a fine continuous line.
Effective Weld Length
The effective weld length is the weld seam as described in the Body Repair Sections. The effective weld length does not include allowances for the run-in/run-out, or termination defects, (start/stop), of the weld seam. It is permissible that the overall weld length is longer than detailed in the repair section, as the overall weld will include a minimum of 5mm at both the start and the stop of the weld seam, provided the function of the part is not affected, or the weld finishes on the edge of a panel.
Post Weld Checks
Weld inspections take the form of a visual examination, non-destructive and destructive testing.
Visual Examination
A visual examination of fusion welds should be carried out in accordance with the acceptance criteria detailed in the following Imperfections/Defect Levels table.
Imperfection/Defect Levels Table
Non Destructive
Dye penetrate testing MUST be used for detection of discontinuities, such as cracks, laps, folds, porosity and lack of fusion that are open to the surface of the material. Typical defects include start, (cold start/incomplete fusion) and stop, (crater cracking), defects within a fusion weld run. In addition to this lack of fusion/coalescence at the weld toe, solidification cracks in the weld bead may also be detected.
Non Destructive Crack Inspection Process
Use the product as listed in the Approved Materials Section, this product is supplied within the Category A tool kit. The product is an aerosol applied dye system. It is designed to penetrate the finest cracks and flaws to facilitate detection, the system includes: Cleaner, Penetrant and Developer.
The process is as follows:
- 1. Use the cleaner to de-grease/clean the test area, then wipe with a lint free cloth.
- 2. When the surface is completely dry, apply the penetrant. Cover the test area and allow a minimum contact time of 10 minutes.
- 3. Remove excess penetrant from the surface with a lint free cloth wetted with the cleaner.
- 4. Apply a THIN film of the developer and leave for a minimum of 10 minutes to draw up the retained dye from flaws or cracks.
- 5. Suspect areas should then be examined under natural or electric light for signs of flaws and/or cracks. Cracks will show up as lines whilst porosity will appear as pin holes.
Destructive Testing
Each test weld should be pulled apart to check the quality and penetration of the weld.