ecu LAND ROVER DEFENDER 1999 Workshop Manual

76CHASSIS AND BODY
32
REPAIR
3.Remove sill button guide.
4.Remove 2 studs securing trim casing.
5.Using a trim removal tool, release 11 fasteners
and remove trim casing.
NOTE: Do not carry out further
dismantling if component is removed for
access only.
6.Remove fasteners and anti-vibration pad from
trim casing
Refit
7.Fit anti-vibration pad and fasteners to trim
casing.
8.Position trim casing, align fasteners with holes in
door and press firmly into position.
9.Fit trim studs to casing.
10.Fit sill button guide.
11.Fit escutcheon to door handle and secure with
screw.
12.Fit door pull and secure with screws.
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CHASSIS AND BODY
33
REPAIR TRIM CASING - TAIL DOOR - FROM 02MY
Service repair no - 76.34.09
Remove
1.Remove 2 bolts securing rear door grab handle,
remove handle.
2.Remove escutcheon.
3.Carefully release 9 fasteners securing trim
casing to rear door and remove casing.
NOTE: Do not carry out further
dismantling if component is removed for
access only.4.Remove 9 fasteners from trim pad.
Refit
5.Fit fasteners to trim casing.
6.Position trim casing and secure fasteners.
7.Fit escutcheon.
8.Fit grab handle and tighten bolts to10 Nm (7
lbf.ft).
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CHASSIS AND BODY
35
REPAIR LOCK - TAIL DOOR - FROM 02MY
Service repair no - 76.37.16
Remove
1.Remove tail door trim casing.See this Section.
2.Remove 4 nuts securing tail door lock.
3.Partially withdraw lock assembly, carefully
disconnect central door locking rod from fulcrum
arm.
4.Remove lock assembly.
5.Remove door lock gasket.
NOTE: Do not carry out further
dismantling if component is removed for
access only.
6.Insert key in lock, depress lock barrel plunger
and withdraw barrel from lock.Refit
7.Fit new barrel to lock.
8.Fit new door lock gasket.
9.Fit door locking rod to fulcrum, align lock. Fit and
tighten nuts to10 Nm (7 lbf.ft ).
10.Close door and check for correct latching with
striker. Adjust striker if necessary.See
Adjustment.
11.Fit tail door trim casing.See this Section.
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76CHASSIS AND BODY
36
REPAIR LOWER FASCIA PANEL - FROM 02MY
Service repair no - 76.46.05
Service repair no - 80.10.12
NOTE: This procedure also covers
removal of the air distribution control
cable, 80.10.12.
Remove
1.Disconnect battery negative lead.See
ELECTRICAL, Repair.
2.Remove steering column nacelle.See
STEERING, Repair.
3.Remove fascia console.See this Section.
4.Remove air vent control knobs.
5.Remove 6 screws, remove fascia closing panel
and collect nut plate.
6.Remove speakers.See ELECTRICAL, Repair.
7.Remove 2 screws and remove both door check
strap covers.
8.Remove 3 screws and remove end cap from
lower fascia panel.
9.Loosen grub screw and clamp plate bolt
securing air distribution cable. Release cable
from control lever.
10.Release screen demister tubes from lower fascia
panel.
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CHASSIS AND BODY
37
REPAIR
11.Remove 2 screws securing fuse cover and
remove cover.
12.Remove 7 screws securing lower edge of fascia
panel.
13.Remove footwell cover retaining plates.
14.Remove 2 nuts and remove lower fascia panel.
NOTE: Do not carry out further
dismantling if component is removed for
access only.
15.Remove 21 screws and release air duct cover.
16.Loosen trunnion screw, remove air distribution
cable and duct cover.Refit
17.Fit air distribution cable to duct cover and fit
inner cable to vent flap trunnion.
18.Tighten vent flap trunnion screw to6Nm(4
lbf.ft)and bend cable end to secure.
19.Fit duct cover to lower fascia and fit and tighten
screws.
20.Check condition of seal between heater and
lower fascia, if damaged replace.
21.Carefully fit lower fascia panel and ensure
harness route is correct.
22.Secure lower fascia panel with screws and
tighten nuts to10 Nm (7 lbf.ft).
23.Fit fuse cover and secure with screws.
24.Connect demister tubes to lower fascia panel.
25.Raise air distribution lever to screen demist
position and close footwell vent.
26.Connect air distribution cable to lever, tighten
grub screw and outer cable clamp.
27.Fit end cap to fascia and secure with screws.
28.Fit check strap covers and secure with screws.
29.Fit speakers.See ELECTRICAL, Repair.
30.Fit fascia closing panel.
31.Fit nut plate and fit screws to secure nut plate
and closing panel.
32.Fit knobs to air vent control levers.
33.Fit fascia console.See this Section.
34.Fit steering column nacelle.See STEERING,
Repair.
35.Connect battery negative lead.See
ELECTRICAL, Repair.
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77 - PANEL REPAIRS
CONTENTS
Page
INFORMATION
BODY REPAIRS 1..................................................................................................
ELECTRONIC CONTROL UNITS (ECU’s) 3..........................................................
BODY DIMENSIONS
CHASSIS AND BODY 1..........................................................................................
CHASSIS FRAME ALIGNMENT 2..........................................................................
GAP AND PROFILE INFORMATION 9...................................................................
SEALING AND CORROSION PROTECTION
APPROVED MATERIALS 1....................................................................................
APPLICATION EQUIPMENT 4...............................................................................
CORROSION PROTECTION 8...............................................................................
CAVITY WAX 12.....................................................................................................
SEALANTS AND ADHESIVES 17..........................................................................
WATER LEAKS 28..................................................................................................
PANELS
SERVICEABLE PANELS 1.....................................................................................
PROCEDURES
GENERAL WELDING PRECAUTIONS 1...............................................................
PANEL REPLACEMENT PROCEDURE 2..............................................................
REPAIR PROCEDURES 6......................................................................................
REPAIR
WING LOWER FRONT 1........................................................................................
HEADLAMP MOUNTING PANEL 1........................................................................
WING UPPER - LH 2..............................................................................................
WING UPPER - RH 2..............................................................................................
WHEEL ARCH - FRONT 3......................................................................................
BULKHEAD ASSEMBLY 3......................................................................................
SCREEN APERTURE 4..........................................................................................
SILL - FRONT 5......................................................................................................
’B/C’&’D’POST 5..................................................................................................
CORNER CAPPING 6.............................................................................................
BODY SIDE CAPPING 6.........................................................................................
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PANEL REPAIRS
3
INFORMATION 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 diconnected 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.See ELECTRICAL
PRECAUTIONS section.
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PANEL REPAIRS
1
REPAIR WING LOWER FRONT
Remove
1.Disconnect both battery leads, negative lead
first. system.
2.Remove wheel arch eyebrow.
3.Remove wheel arch liner.
4. RH side:Remove aerial.
5.Remove air intake hose.
6.Remove bolts securing lower wing.
Refit
7.Prepare and clean panel joint faces.
8.Reverse removal procedure.HEADLAMP MOUNTING PANEL
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect all ECUs.
3.Remove radiator.See COOLING SYSTEM,
Repair.
4.Recover refrigerant from A/C system.See AIR
CONDITIONING, Repair.
5.Remove headlamp.See ELECTRICAL,
Repair.
6. LH side:Remove screen washer bottle.See
WIPERS AND WASHERS, Repair.
7. RH side:Position PAS reservoir aside.
8.Remove bolts and release welds securing panel,
remove panel.
Refit
9.Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding as
shown.
10.Reverse removal procedure.
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77PANEL REPAIRS
2
REPAIR WING UPPER - LH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove headlamp.See ELECTRICAL,
Repair.
3.Remove headlamp mounting panel.See this
Section.
4.Remove radiator.See COOLING SYSTEM,
Repair.
5.Recover refrigerant from A/C system.See AIR
CONDITIONING, Repair.
6.Remove receiver drier.See AIR
CONDITIONING, Repair.
7.Remove relevant A/C pipes.
8.Remove relevant heater intake pipes.
9.Remove screen washer bottle.
10.Remove wheel arch liner.See CHASSIS AND
BODY, Repair.
11.Remove bolts and release welds securing panel,
remove panel.
Refit
12.Prepare and clean panel joint faces.
13.Reverse removal procedure.
14.Align headlamps.See ELECTRICAL,
Adjustment.WING UPPER - RH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove headlamp.See ELECTRICAL,
Repair.
3.Remove headlamp mounting panel.See this
Section.
4.Remove radiator.See COOLING SYSTEM,
Repair.
5.Recover refrigerant from A/C system.See AIR
CONDITIONING, Repair.
6.Remove relevant A/C pipes.
7.Position PAS reservoir aside.
8.Remove wheel arch liner.See CHASSIS AND
BODY, Repair.
9.Remove aerial.
10.Remove vacuum solenoid valve.
11.Release clips securing coolant reservoir.
12.Remove bolts and release welds securing panel,
remove panel.
Refit13.Prepare and clean panel joint faces.
NOTE: LH panel shown
14.Reverse removal procedure.
15.Align headlamps.See ELECTRICAL,
Adjustment.
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77PANEL REPAIRS
4
REPAIR SCREEN APERTURE
Remove
1.Disconnect both battery leads, negative lead
first.
2.Raise side of vehicle.
3.Remove front and centre headlining sections.
4.Remove both’A’post upper trims.
5.Remove front door aperture seals.
6.Release upper front corner of rear door aperture
seal.
7.Remove both wiper arms.See WIPERS AND
WASHERS, Repair.
8.Remove front screen.
9.Remove all roof fixings, back to the’B/C’post.
10.Release sealant securing front edge of roof.
11.Insert wedges into top of both’B/C’posts. This
will allow access for removal of screen aperture.
12.With assistance remove screen aperture.Refit
13.Prepare and clean panel joint faces.
14.Reverse removal procedure. Fit new foam seal
to top edge of aperture.
NOTE: When refitting, ensure screen
aperture is correctly fitted onto location
pins in bulkhead.
15.When applying sealant to top edge of aperture,
the correct colour sealant must be used, see
note below.
NOTE: White roof vehicles use a white
sealant. Coloured roof vehicles use a
black sealant.
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