wheel LAND ROVER DEFENDER 1999 Manual Online

76CHASSIS AND BODY
8
REPAIR LINER - FRONT WHEEL ARCH
Service repair no - 76.10.48
Remove
1.Raise front of vehicle.
WARNING: Support on safety stands.
2.Remove front wheel.
3.Support axle weight with jack.
4.Remove 6 screws securing damper top cover to
inner wing, remove cover.
5.Remove nut securing damper to top mounting
bracket and collect rubber bush and 2 washers.
6.Remove 4 nuts securing damper to mounting
bracket and collect washers.
7.Remove damper top cover.
8.Remove 4 screws and 3 studs securing liner to
inner wing. Remove liner.
Refit
9.Position liner, secure with screws and studs.
10.Fit damper mounting bracket and tighten nuts.
11.Position damper to mounting bracket, fit rubber
bush and washers and tighten nut.
12.Fit damper cover to inner wing and secure with
screws.
13.Fit road wheel.
14.Remove stands and lower vehicle.
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76CHASSIS AND BODY
10
REPAIR DOOR - TAIL - REMOVE
Service repair no - 76.28.19.99
Remove
1.Remove 3 nuts and remove spare wheel.
2.Remove bolt securing check strap to body.
3.Release harness grommet from harness cover,
disconnect connectors and multiplug.
4.Release harness cover and harness from body.
5.With assistance, remove 6 screws securing door
hinges to body and remove door.
Refit
6.With assistance, position door and fit but do not
tighten bolts.
7.Position check strap and tighten bolt.
8.Align door to body and tighten bolts.
9.Position harness through body and secure
harness cover.
10.Secure harness connectors and multiplug.
11.Secure harness grommet to body.
12.Position spare wheel to tail door and tighten
nuts.
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CHASSIS AND BODY
11
REPAIR GLASS/SEALING RUBBER - TAIL DOOR - UP TO
02MY
Service repair no - 76.31.22
Remove
1.Remove high level stop lamp.See
ELECTRICAL, Repair.
2.Remove 3 nuts and remove spare wheel.
3.Raise cover, remove nut and remove rear wiper
arm assembly.
4.Disconnect 2 HRW Lucars.
5.Remove 30 screws securing door glass
retainers.
6.Remove door glass retainers.
7.Remove door glass sealing strips.
8.Release and remove door glass.Refit
9.Clean old sealant from glass aperture.
10.Apply sealant to glass aperture.
11.Position door glass, fit sealing strips and glass
retainers and secure with screws.
12.Connect HRW lucars.
13.Fit high level stop lamp.See ELECTRICAL,
Repair.
14.Fit rear wiper arm assembly and secure with nut.
15.Position spare wheel and secure with nuts.
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CHASSIS AND BODY
19
REPAIR LOWER FASCIA PANEL - UP TO 02MY
Service repair no - 76.46.05
Remove
1.Disconnect battery negative lead.
2.Remove steering wheel.See STEERING,
Repair.
3.Remove 7 screws securing nacelle to steering
column.
4.Remove 2 halves of nacelle from steering
column.
5.Remove instrument pack.See ELECTRICAL,
Repair.
6.Remove 3 screws securing heater control cable
assembly to end of fascia.
7.Release heater control cable assembly from
fascia and move aside.
8.Release HRW, Rear Fog Guard Lamp, and
Hazard Warning switches from fascia.
9.Disconnect multiplugs and Lucars from switches.
10.Collect switches.
11.Remove locking rings from both front speakers.
12.Remove 4 screws securing each speaker to
fascia.
13.Disconnect multiplugs from speakers and
remove both front speakers.
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CHASSIS AND BODY
23
REPAIR 59.Fit radio housing to fascia and secure with trim
studs.
60.Position radio to fascia and connect multiplugs
and aerial.
61.Fit radio to fascia.
62.Fit crash pad to fascia and secure with screws.
63.Fit both demister vents to crash pad and secure
with screws.
64.Fit grab handle to fascia and secure with screws.
65.Fit Land Rover decal to grab handle.
66.Position both front speakers to fascia and
connect multiplugs.
67.Fit speakers to fascia and secure with screws.
68.Fit locking rings to speakers.
69.Connect multiplugs and Lucars to HRW, Rear
Fog Guard Lamp, and Hazard Warning
Switches.
70.Fit switches to fascia.
71.Position heater controls to fascia and secure
with screws.
72.Fit instrument pack.See ELECTRICAL,
Repair.
73.Fit 2 halves of nacelle to steering column and
secure with screws.
74.Fit steering wheel.See STEERING, Repair.
75.Reconnect battery negative lead.PANEL - MOUNTING - FRONT DOOR - FROM 02MY
Service repair no - 76.11.28
Remove
1.Remove plastic sheet.See this Section.
2.Lower glass and remove 2 bolts securing door
glass to regulator.
3.Release glass from regulator, raise and wedge
in raised position.
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76CHASSIS AND BODY
30
REPAIR Refit
7.Insert glass into channels and carefully push to
top of frame.
8.Secure glass channels with screws. Ensure
screw heads are down below bottom of channels
to prevent damage to glass.
9.Fit inner and outer waist seal to door.
10.Fit check strap.
11.Fit check strap torsion bar and tighten nuts to10
Nm (7 lbf.ft).
12.Fit rear door mounting panel.See this Section.GLASS/SEALING RUBBER - TAIL DOOR - FROM
02MY
Service repair no - 76.31.22
Remove
1.Remove spare wheel from tail door.
2.Raise nut cover, remove nut and release wiper
arm.
3.Open rear door.
4.Remove CHMSL assembly.See
ELECTRICAL, Repair.
5.Disconnect 4 Lucar connections.
6.With assistance, from inside of vehicle apply
pressure to glass, relieve seal lip and carefully
remove glass.
WARNING: Wear suitable eye protection
when removing and refitting glass.
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CHASSIS AND BODY
31
REPAIR 7.Remove seal from glass.
CAUTION: Lay glass on felt covered
supports and be careful not to damage the
obscuration band. Do not stand on edge
as this can cause chips which subsequently
develop into cracks.
Refit
8.Clean glass and fit seal. Ensure seal is fully
located on glass.
9.Thoroughly clean the tail door glass mounting
flange.
10.Fit drawstring to seal.
11.Lubricate seal.
12.With assistance, position glass and seal to
aperture, locate lower edge and fit seal using
drawstring.
13.Clean glass and check seal fit.
14.Connect Lucars to heated rear screen.
15.Fit CHMSL assembly.See ELECTRICAL,
Repair.
16.Fit wiper arm to spindle, align blade to glass and
tighten nut to18 Nm (13 lbf.ft).
17.Fit spare wheel and tighten nuts to45 Nm (33
lbf.ft).TRIM CASING - FRONT DOOR - FROM 02MY
Service repair no - 76.34.01
Remove
1.Remove 2 screws securing door pull and
remove door pull.
2.Remove screw securing door release
escutcheon and remove escutcheon.
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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
1
BODY DIMENSIONS CHASSIS AND BODY
Chassis
The chassis on all Defender variants are of the box
section, ladder type construction, manufactured from
2 mm (14swg) steel and treated with zinc phosphate,
cathodic electro coated, followed by waxing in the rear
crossmember.
Outriggers and angled brackets welded to the chassis
support suspension and axle components and are
also used as body mounting points. A detachable box
section crossmember, located between the two
chassis longitudinals is fitted to facilitate main gearbox
and tranfer box assembly removal.Should chassis damage occur, a comprehensive
range of components are available, including body
support outriggers, cross members and radius arm
mounting brackets. ALWAYS fit genuine parts that are
fully guaranteed and to original equipment
specification, fitted with Land Rover’s BS 5135
welding standard.
Body
All body panels, with the exception of the fascia
bulkhead, are manufactured from aluminium alloy.
Galvanized steel is used for the front wheel arches to
give optimum protection. Most panels are also treated
with zinc phosphate and cathodic electro coated with
polyester surfacer, and are bolted to the welded
chassis.
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77PANEL REPAIRS
4
BODY DIMENSIONS LAND ROVER 90
CHASSIS ALIGNMENT DIMENSIONS
A - Front Datum
B - Chassis Datum
C - Front axle centre line
D - Rear axle centre line
1.239,0 - 236,5 mm
2.82,0 - 79,5 mm
3.633 mm
4.2420,6 - 2418,6 mm
5.2306,4 - 2305,4 mm
6.981,2 - 978,7 mm
7.182,7 mm
8.41,5 - 37,0 mm
9.252 - 250 mm10.110 mm
11.2360mm - Wheelbase
12.636 - 634 mm
13.488 - 482 mm
14.488 - 482 mm
15.3431,1 - 3426,1 mm
16.588,3 - 586,3 mm
17.2313,8 - 2311,8 mm
18.590,5 mm
19.295,25 mm
20.519,30 - 517,30 mm
21.259,80 - 258,50 mm
22.1242,6 - 1240,6 mm
23.642,5 - 639,5 mm24.750,9 mm
25.439,5 - 436,5 mm
26.136,5 mm
27.299,5 - 295,5 mm
28.103 - 100 mm
29.131,5 - 126,5 mm
30.705,5 - 704,5 mm
31.705,5 - 704,5 mm
32.42,2 - 40,2 mm
33.491 - 486 mm
34.594,2 - 593,4 mm
35.283,0 - 282,2 mm
36.32,25 - 31,25 mm
37.397 - 395 mm
Engine mounting dimensions - section V-V
Section V-V, Tdi and Td5 engine mounting bracket dimensions. The dimensions are applicable to all derivatives.
Tdidimensions:
A = 276.5
B = 553
C = 127.9
D = 317.4
E = 4 degreesTd5dimensions:
A = 273.2
B = 546.5
C = 187.8
D = 374.3
E = 4 degrees
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