steering LAND ROVER DEFENDER 1999 Owner's Manual

57 - STEERING
CONTENTS
Page
REPAIR
STEERING COLUMN - UPPER - Td5 1.................................................................
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STEERING
1
REPAIR STEERING COLUMN - UPPER - Td5
Service repair no - 57.40.01
Remove
1.Ensure road wheels and steering wheel are set
in the straight ahead position.
2.Loosen 2 clips securing air inlet pipe between
turbo and inlet air filter.
3.Remove air inlet pipe.
4.Mark relationship between the upper steering
column and the lower steering column universal
joint.
5.Remove bolt securing upper column to lower
column universal joint.
6.Remove steering colum nacelle.See this
Section.
7.Remove instrument pack.See
INSTRUMENTS, Repair.
8.Disconnect 3 column switch multiplugs.
9.Loosen column switch clamping screw.
10.Remove column switch assembly from steering
column.
11.Disconnect 4 Lucars from rear of ignition switch.
NOTE: Take note of Lucars correct fitted
position. Details can also be found in the
Electrical Reference Library.
12.Remove passive coil.See ELECTRICAL,
Repair.
13.Drill out 2 shear bolts securing ignition barrel to
column.
14.Remove ignition barrel.
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57STEERING
2
REPAIR 15.Remove brake servo.See BRAKES, Repair.
16.Release ABS modulator multiplug from side of
brake pedal box.
17.Release mat from underside of fascia to gain
access to brake pedal box mounting bolts.
18.Remove 6 bolts securing brake pedal box to
bulkhead.
19.Disconnect 2 brake pedal switch Lucars.
20.Carefully remove brake pedal box assembly and
collect gasket.
21.Remove bolt securing column upper tie bar to
column.
22.Remove 2 bolts securing upper column to lower
mounting bracket.
23.Remove 2 bolts securing 2 halves of column
upper clamp.
24.Remove 2 bolts securing column upper clamp to
mounting bracket.
25.Remove column upper clamp and collect rubber
packing.
26.Remove 2 bolts securing column upper
mounting bracket to bulkhead.
27.Release upper column from lower column and
manouvre mounting bracket and upper column
assembly from vehicle.
28.Remove mounting bracket from column.
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STEERING
3
REPAIR Refit
NOTE: The steering column is a
non-servicable component and can only
be serviced as a complete assembly.
29.Fit mounting bracket to column and manouvre
assembly into position.
NOTE: Ensure marks on upper and lower
columns are aligned.
30.Loosely fit bolts securing mounting bracket to
bulkhead.
31.Fit upper clamp and rubber packing to column.
32.Loosely fit bolts securing upper clamp to
mounting bracket.
33.Loosely fit bolts securing 2 halves of upper
clamp.
34.Loosely fit bolts securing column lower mounting
bracket.
35.Fit bolt securing upper tie bar to steering column
and tighten to22 Nm (16 lbf.ft).
36.Tighten mounting bracket to bulkhead bolts,
clamp bolts, and lower mounting bolts.
M6 bolts =9 Nm (6 lbf.ft)
M8 bolts =22 Nm (16 lbf.ft)
37.Manouvre brake pedal box assembly and NEW
gasket into position in vehicle.
38.Tighten bolts securing brake pedal box to
bulkhead to25 Nm (18 lbf.ft)
39.Connect brake pedal switch Lucars.
40.Reposition mat to underside of fascia.
41.Secure ABS modulator multiplug to side of brake
pedal box.
42.Fit brake servo.See BRAKES, Repair.
43.Fit ignition switch to steering column, ensuring
inner shaft slot aligns with steering lock plunger.
44.Evenly tighten clamp bolts, but DO NOT shear at
this stage.
45.Temporarily fit steering wheel and check for
correct operation of switch and lock.
46.Remove steering wheel.
47.Fully tighten ignition switch bolts until heads
shear.48.Connect Lucars to rear of ignition switch.
49.Fit passive coil to ignition switch and connect
multiplug.
50.Fit switch assembly to steering column and
tighten clamping screw.
51.Connect column switch multiplugs.
52.Fit instrument pack.See INSTRUMENTS,
Repair.
53.Fit steering column nacelle.See this Section.
54.Fit bolt securing upper column to lower column
universal joint and tighten to25 Nm (18 lbf.ft).
55.Fit air inlet pipe between turbo and inlet air filter
and secure with clips.
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57STEERING
4
REPAIR
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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
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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PANEL REPAIRS
1
INFORMATION BODY REPAIRS
Body shells are of riveted, bolted and welded
construction and are bolted to the chassis frame.
It is essential that design dimensions and strength are
restored in accident rectification. It is important that
neither structural weakness nor excessive local
stiffness are introduced into the vehicle during body or
chassis repair.
Repairs usually involve a combination of operations
ranging from straightening procedures to renewal of
either individual panels or panel assemblies. The
repairer will determine the repair method and this
decision will take into account a balance of economics
between labour and material costs and the availability
of repair facilities in both equipment and skills. It may
also involve considerations of vehicles down-time,
replacement vehicle availability and repair turn-around
time.
It is expected that a repairer will select the best and
most economic repair method possible, making use of
the facilities available. The instructions given are
intended to assist a skilled body repairer by expanding
approved procedures for panel replacement with the
objective of restoring the vehicle to a safe running
condition and effecting a repair which is visually
acceptable and which, even to the experienced eye,
does not advertise the fact that it has been damaged.
This does not necessarily mean that the repaired
vehicle will be identical in all respects with original
factory build. Repair facilities cannot always duplicate
methods of construction used during production.
The panel repairs shown in this section are all based
on a 110 Station Wagon. Therefore all illustrations
and text relate only to this model. Although certain
areas of the vehicle, such as the front end, are
relevant to all models.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and suspension
geometry checked after completion and if necessary a
road test of the vehicle is carried out, particularly
where safety related items are concerned.Where major units have been disconnected or
removed, it is necessary to ensure that fluid levels are
checked and topped up when necessary. It is also
necessary to ensure that the repaired vehicle is in a
roadworthy condition in respect of tyre pressures,
lights, washer fluid etc.
Body repairs often involve the removal of mechanical
and electrical units as well as associated wiring.
Where this is necessary use the relevant section in
this manual.
Taking into consideration the differences in body
styles, steering and suspension systems as well as
engine and suspension layouts, the location of the
following components as applicable to a particular
vehicle is critical:
Front suspension upper damper
mountings.
Front suspension or sub frame mountings.
Engine mountings on RH and LH chassis
longitudinals.
Rear suspension upper damper mountings.
Rear suspension mountings or lower
pivots.
Steering rack mountings.
Additional points which can be used to check
alignment and assembly are:
Inner holes in crossmember - side - main
floor.
Holes in valance front assembly.
Body to chassis mounting holes.
Holes in rear floor.
Holes in rear lower panels or extension
rear floor.
Fuel tank mountings.
Apertures for windscreen, backlight, bonnet and doors
can be checked by offering up an undamaged
component as a gauge and also by measuring known
dimensions.See BODY DIMENSIONS section.
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