belt LAND ROVER DEFENDER 1999 Owner's Manual

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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77PANEL REPAIRS
12
SEALING AND CORROSION PROTECTION CAVITY WAX
Cavity Wax Injection
Box sections treated with cavity wax are shown in this
section. Repairs affecting these areas must include
re-treatment with an approved cavity wax, using the
access points illustrated. In addition, all interior
surfaces which have been disturbed during repairs
must be wax injected whether they have been treated
in production or not. This includes all box members,
cavities, door interiors etc. It is permissible to drill
extra holes for access where necessary, provided
these are not positioned in load-bearing members.
Ensure that such holes are treated with a suitable zinc
rich primer, brushed with wax and then sealed with a
rubber grommet.
Prior to wax injection, ensure that the cavity to be
treated is free from any contamination or foreign
matter. Where necessary, clear out any debris using a
compressed air supply.
Carry out wax injection after final paint operations.
During application, ensure that the wax covers all
flange and seam areas and that it is applied to all
repaired areas of both new and existing panels.
NOTE: Apply cavity wax AFTER the final
paint process and BEFORE refitting of any
trim components.It should also be noted that new panel assemblies and
body shells are supplied without wax injection
treatment which must be carried out after repairs.
Effective cavity wax protection is vital. Always observe
the following points:
Complete all finish paint operations before
wax application.
Clean body panel areas and blow-clean
cavities if necessary, before treatment.
Maintain a temperature of 18°C (64°F)
during application and drying.
Check the spray pattern of injection
equipment.
Mask off all areas not to be wax coated
and which could be contaminated by wax
overspray.
Remove body fixings, such as seat belt
retractors, if contamination is at all likely.
Move door glasses to fully closed position
before treating door interiors.
Treat body areas normally covered by trim
before refitting items.
Check that body and door drain holes are
clear after the protective wax has dried.
Keep all equipment clean, especially wax
injection nozzles.
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PANEL REPAIRS
1
PROCEDURES GENERAL WELDING PRECAUTIONS
The following pages show the procedures to follow
when using welding for repairs. No resistance spot
welds have been used in any of the repairs.
The Aluminium alloy used on all Defender models is a
combination of Aluminium and Magnesium.
When converting a MIG welder for use on Aluminium
it is essential the following components are changed.
The materials shown in brackets are the correct
materials to use:
Torch liner (Teflon or Carbon Fibre)
Contact tip
Feed rollers/wheels
Correct Filler wire (combination of
Aluminium and Magnesium)
Shielding gas (Argon)
When carrying out welding operations the following
criteria must be observed:
Where resistance spot welds have been
used in production, these must be replaced
with either MIG plug welds or rivets.
To replace each production spot weld an 8
mm (0.31 in) hole must be drilled and/or
punched, and a MIG weld then made in its
place. The number of plug welds must
match exactly the number of spot welds
which have been removed.
Where holes are left in an existing panel
after removal of the spot welds, a single
MIG plug weld will be made in each hole as
appropriate.
When MIG welding ensure the correct wire
is used.
The replacement welds in the welding
diagrams are denoted by the following
symbols:
A. MIG Plug welds
B. MIG seam weld
Seat Belt Anchorages
Seat belt anchorages are safety critical. When making
repairs in these areas it is essential to follow design
specifications.
Where possible, the original production assembly
should be used, complete with its seat belt
anchorages, or the cut line should be so arranged that
the original seatbelt anchorage is not disturbed.
All welds within 250mm (9.9in.) of seat belt
anchorages must be carefully checked for weld
quality, including spacing of spot welds. A crack
detection process must be carried out in these areas.
WARNING: Body parts incorporating seat
belt anchorages MUST be renewed
completely if damaged beyond repair, as
the welds in these areas are safety critical and
cannot be disturbed.
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PANEL REPAIRS
3
PROCEDURES
4.Cut away the bulk of the panel as necessary
using an air saw.
NOTE: On certain panel joints MIG welds
and braze should be removed using a
sander where possible, before cutting out
the panel bulk.
5.Separate spot welded joints and remove panel
remnants using hammer, bolster chisel and
pincers.Prepare Old Surfaces
6.Clean all panel joint edges to a bright smooth
finish, using a belt-type sander.
NOTE: Prior to sanding, remove remaining
sealant using a hot air gun to minimise the
risk of toxic fumes caused by generated
heat.
WARNING: Care must be taken to avoid
excessive heat build up which may be
caused by this equipment.
7.Straighten existing joint edges using shaping
block and hammer.
CAUTION: Where significant straightening
is required, heat must be applied to the
area to avoid stretching the Aluminium.
CAUTION: All tools used for working with
Aluminium must be kept separate from
those used on steel.
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77PANEL REPAIRS
4
PROCEDURES Prepare New Surfaces
8.Prepare new panel joint edges for welding by
sanding to a bright finish. This must include inner
as well as outer faces.
9.Drill holes in new panel, in the equivalant spot
weld positions.
10.Apply adhesive sealant to panel joint surfaces.
11.All mating faces that have sealant applied to
them must be cleaned using a suitable solvent.
The majority of Aluminium sealants have a
primer/pre-treatment included with them.
CAUTION: Do not use Petroleum Spirit,
Alcohol or Paint Thinners to clean mating
faces.Offer Up and Align
Offer up new panel and align with associated panels.
Clamp into position using welding clamps or Mole
grips. Where a joggle or brace joint is being adopted,
make a set in the original panel joint edge or insert a
brace behind the joint.
NOTE: In cases where access for welding
clamps is difficult, it may be necessary to
use tack welds.
12.Dress MIG tack welds using a sander with 36 grit
disc, or a belt-type sander where access is
limited.
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PANEL REPAIRS
5
PROCEDURES Welding
13.When plug welding, begin weld approximately 15
mm (0.6’) from hole. This will allow the weld
area to be preheated which will enhance weld
penetration. It also allows the operator to see
more easily where penetration takes place. Fill
hole with weld by moving in a circular direction
around the hole.
14.When MIG seam welding do not carry out
lengthy operations. Divide the welds into short
operations, this will reduce the chances of
overheating the workpiece which inturn will avoid
distortion and strain.
15.Dress all welds using a sander with 36 grit disc,
or a belt-type sander and/or wire brush.
CAUTION: Only use a Stainless Steel wire
brush for Aluminium.
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PANEL REPAIRS
5
REPAIR SILL - FRONT
Remove
NOTE: The procedure to replace the rear
sill section is the same as the front.
1.Remove bolts securing sill to body, discard seal.
Refit
NOTE: Front sill
NOTE: Rear sill
2.Prepare and clean panel joint faces. Refit new
seal.
3.Reverse removal procedure.’B/C’&’D’POST
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove rear door and striker.
3.Remove front seat belt reel.See CHASSIS
AND BODY, Repair.
4.Remove front and rear carpets.
5.Remove front seat.
6.Remove rear seat.
7.Remove front, centre and rear sections of
headlining.
NOTE: Assembly is held on with bolts.
Refit
8.Prepare and clean panel joint faces.
9.Reverse removal procedure.
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AIR CONDITIONING
1
REPAIR COMPRESSOR
Service repair no - 82.10.20
Remove
1.Remove engine acoustic cover.See ENGINE ,
Repair.
2.Depressurise A/C system.See Adjustment.
3.Remove auxiliary drive belt.See
ELECTRICAL, Repair.
4.Drain cooling system.See COOLING
SYSTEM, Adjustment.
5.Disconnect multiplug from compressor.
6.Remove 2 bolts securing air conditioning pipes
to compressor and discard’O’rings.
CAUTION: Immediately cap all air
conditioning pipes to prevent ingress of
dirt and moisture into the system.
7.Release clips and disconnect top hose from
coolant elbow and heater pipe.
8.Remove 4 bolts securing compressor to
mounting bracket.
9.Remove compressor.Refit
10.Position compressor to mounting bracket and
tighten bolts to25 Nm (18 lbf.ft).
11.Remove caps from compressor and pipe
connections.
12.Clean compressor and pipe connections.
13.Lubricate new’O’rings with refrigerant oil and fit
to compressor.
14.Position A/C pipes to compressor and tighten
bolts to9 Nm (7 lbf.ft).
15.Connect multiplug to compressor.
16.Position top hose and secure with clips.
17.Refill cooling system.See COOLING SYSTEM,
Adjustment.
18.Fit auxiliary drive belt.See ELECTRICAL,
Repair.
19.Recharge A/C system.See Adjustment.
20.Fit engine acoustic cover.See ENGINE ,
Repair.
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86 - ELECTRICAL
CONTENTS
Page
DESCRIPTION AND OPERATION
SECURITY AND CENTRAL DOOR LOCKING 1....................................................
SECURITY AND CENTRAL DOOR LOCKING 2....................................................
ANTI-THEFT ALARM - FROM 02MY 3...................................................................
IMMOBILISATION SYSTEM - FROM 02MY 12......................................................
CENTRAL DOOR LOCKING (CDL) - FROM 02MY 15...........................................
ANTI-THEFT ALARM SYSTEM SELF TEST 17.....................................................
FASCIA CONSOLE 18............................................................................................
HEATED FRONT SCREEN - FROM 02MY 20.......................................................
HEATED FRONT SEATS - FROM 02MY 22..........................................................
ELECTRIC FRONT WINDOWS - FROM 02MY 24.................................................
PASSENGER COMPARTMENT FUSE BOX 26.....................................................
UNDER SEAT FUSE BOX 27.................................................................................
ADJUSTMENT
HEADLAMPS - ALIGN BEAM 1..............................................................................
SOLENOID/MOTOR - FRONT DOOR - ADJUST 1................................................
REPAIR
BELT - AUXILLARY DRIVE 1.................................................................................
HARNESS - INJECTORS 1....................................................................................
STARTER MOTOR 2..............................................................................................
CENTRE HIGH MOUNTED STOP LIGHT (CHMSL) - UP TO 02MY 2...................
ALTERNATOR 3.....................................................................................................
HORN - LH 4...........................................................................................................
HEADLAMP 5.........................................................................................................
LAMP - TAIL 6.........................................................................................................
RADIO6 ..................................................................................................................
SPEAKER - FRONT 7.............................................................................................
SWITCH - TRANSMISSION BRAKE 7...................................................................
LAMP - FRONT FLASHER 8..................................................................................
BATTERY - DISCONNECT - FROM 02MY 8..........................................................
MOTOR & REGULATOR - FRONT DOOR - FROM 02MY 9..................................
SWITCH - FASCIA - FROM 02MY 10.....................................................................
HARNESS - FRONT DOOR - FROM 02MY 10.......................................................
SOLENOID/MOTOR - TAIL DOOR - FROM 02MY 11............................................
SOLENOID/MOTOR - FRONT DOOR - FROM 02MY 12.......................................
SOLENOID/MOTOR - REAR DOOR - FROM 02MY 13.........................................
HARNESS - REAR DOOR - FROM 02MY 14.........................................................
REVERSE AND FOG GUARD LAMP - BULB 15....................................................
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