service LAND ROVER DEFENDER 1999 Workshop Manual

76CHASSIS AND BODY
4
REPAIR WING - FRONT
Service repair no - 76.10.24
Remove
1.Remove wheel arch liner.See this Section.
2.Remove front grille.See this Section.
3.Release fixings and remove cooling fan cowl.
4.Remove air cleaner grille from front wing.
5.Remove 4 screws securing air intake elbow to
wing.
6.Remove 7 screws and remove heater air intake
grille from wing.
7.Remove 2 bolts securing heater air intake
bracket to inner wing. Remove bracket.
8.Remove heater air intake from wing and collect
seal.
9.Remove 2 bolts securing EGR solenoid to inner
wing and lay aside.
10.Remove 3 studs securing expansion tank pipe to
inner wing.
11.Remove 2 bolts securing PAS reservoir to inner
wing and lay aside.
12.Remove 4 bolts securing outer wing to inner
wing.
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CHASSIS AND BODY
7
REPAIR Refit
29.Fit bonnet cable grommet.
30.Fit side repeater lamp to wing.
31.Fit headlamp sealing ring, fit headlamp and
tighten screws.
32.Fit headlamp finisher, side and indicator lamps
and tighten screws.
33.Fit grille support bracket and tighten bolt.
34.With assistance, position and align wing to body
and locate bonnet cable to wing.
35.Connect headlamp, indicator, side lamp and side
repeater lamp multiplugs.
36.Fit bolt securing wing to bulkhead.
37.Fit bolts securing wing to’A’post.
38.Fit nut and bolt securing support stay to wing.
39.Fit bolt securing inner and outer wing to chassis.
40.Fit bolts securing radiator bracket to wing.
41.Fit bolts securing outer wing to inner wing.
42.Align wing and finally tighten all bolts.
43.Position wheel arch extension to wing, and fit
securing studs.
44.Position PAS reservoir to wing and tighten bolts.
45.Position expansion tank pipe and secure with
studs.
46.Position EGR solenoid and tighten bolts.
47.Position heater air intake seal and fit air intake.
48.Fit heater air intake bracket and tighten bolts.
49.Fit heater air intake grille and tighten screws.
50.Align air cleaner intake elbow, tighten screws
and fit grille.
51.Fit wheel arch liner.See this Section.
52.Position bonnet release cable to lock and tighten
screw.
53.Fit cooling fan cowl.
54.Fit front grille.See this Section.STEP - FOLDING - REAR DOOR
Service repair no - 76.10.41
Remove
1.Remove 2 bolts securing step to chassis
member, remove step and collect spacers.
Refit
2.Position step, fit spacer washers and tighten
bolts.
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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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CHASSIS AND BODY
9
REPAIR FRONT BUMPER
Service repair no - 76.22.08
Remove
1.Remove 6 screws and remove front grille.
2.Remove 4 through bolts securing front bumper
to chassis longitudinals.
3.Remove front bumper.
Refit
4.Fit front bumper to chassis longitudinals and
secure with bolts.
5.Fit front grille and secure with screws.DOOR - REAR
Service repair no - 76.28.02.99
Remove
1.Remove nut securing door check strap.
2.With assistance remove 4 bolts securing door to
body and remove door.
Refit
3.With assistance position door and fit but do not
tighten bolts.
4.Align door to body aperture and tighten bolts.
5.Fit and tighten check strap nut.
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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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76CHASSIS AND BODY
12
REPAIR SEAT BELT - FRONT
Service repair no - 76.73.13
Remove
1.Remove cap from seat belt guide bolt.
2.Remove bolt securing seat belt guide to’B’post.
3.Release belt from’B’post mounting.
4.Remove 3 bolts securing belt bracket to seat
base.
5.Remove 2 studs securing seat belt retaining clip.
6.Remove retaining clip.
7.Remove bolt securing inertia reel to body.
8.Remove automatic belt assembly.
9.Remove 2 bolts securing stalk to body.
10.Remove stalk.
Refit
11.Position stalk and tighten bolts.
12.Position automatic belt assembly to body and
tighten bolt to38 Nm
13.Unreel portion of belt.
14.Position bracket to seat base, tighten bolts.
15.Position belt to’B’post mounting and tighten bolt
to32 Nm (24 lbf.ft).
16.Fit cap to bolt head.
17.Position belt retaining clip to seat base and
secure with studs.
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CHASSIS AND BODY
13
REPAIR SEAT BELT - CENTRE - REAR
Service repair no - 76.73.20
Remove
1.Remove seat belt bolt caps and remove bolts.
2.Remove seat belt and stalk.
Refit
3.Position seat belt and stalk.
4.Fit and tighten bolts to32 Nm (24 lbf.ft),and fit
bolt caps.SEAT BELT - REAR - SIDE
Service repair no - 76.73.23
Remove
1.Remove cap from seat belt guide bolt.
2.Remove seat belt upper and lower securing
bolts.
3.Remove seat belt guide from’D’post finisher.
4.Remove 2 studs securing finisher to’D’post.
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76CHASSIS AND BODY
14
REPAIR
5.Release finisher from body upper rail and’D’
post.
6.Pull seat belt through’D’post finisher.
7.Remove bolt securing seat belt to’D’post and
remove belt assembly.
Refit
8.Position seat belt assembly to’D’post and
tighten bolt to32 Nm (24 lbf.ft).
9.Extend seat belt and position through’D’post
finisher.
10.Fit and tighten seat belt upper and lower
securing bolts to32 Nm (24 lbf.ft).
11.Secure’D’post finisher to body upper rail.
12.Fit belt guide to’D’post finisher and fit finisher
retaining studs.
13.Fit cap to seat belt bolt.SEAT - REAR
Service repair no - 78.10.48.99
Remove
1.Remove bolts securing rear seat to hinges and
collect spacer.
2.Remove rear seat.
Refit
3.Position rear seat and align to hinges.
4.Fit spacer and tighten bolts.
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CHASSIS AND BODY
15
REPAIR COVER - CUSHION - REAR SEAT
Service repair no - 78.40.04
Remove
1.Remove rear seat.See this Section.
2.Remove 2 bolts securing squab to cushion
frame.
3.Remove squab and collect spacer.
4.Remove 17 screws securing base board to seat
cushion frame and remove board.
5.Remove 2 trim retaining clips.
6.Release cover retainers from seat frame.
7.Remove cover from cushion pad.
Refit
8.Position cover to cushion pad and secure
retainers to seat frame.
9.Fit trim retaining clips.
10.Position base board and tighten screws.
11.Position and align squab to cushion frame.
12.Fit spacer and tighten securing bolts.
13.Fit rear seat.See this Section.
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