brakes LAND ROVER DEFENDER 1999 Owner's Guide

70BRAKES
10
REPAIR FRONT BRAKE PADS - FROM 02MY
Service repair no - 70.40.02
Remove
1.Remove front road wheels.
2.Clean exterior of calipers.
3.Remove split pin from retaining pins.
4.Remove pad retaining pins and anti-rattle
springs.
5.Remove brake pads.
6.Clean exposed parts of pistons, using new brake
fluid. Wipe away excess with a lint free cloth.
7.Using piston clampLRT-70-500press each
piston back into its bore. Ensure that displaced
brake fluid does not overflow from reservoir.
Refit
8.Fit brake pads.
NOTE: Ensure pads are correctly fitted,
with leading edge chamfer fitted as shown.
9.Fit pad retaining pins and anti-rattle springs.
Secure with new split pins.
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BRAKES
11
REPAIR 10.Apply service brake pedal several times to locate
pads.
11.Fit road wheels, remove chassis stands and
jack. Tighten wheel nuts to130 Nm (96 lbf/ft).
12.Check fluid reservoir. Top up if necessary, using
correct grade of fluid.See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.REAR BRAKE PADS - FROM 02MY
Service repair no - 70.40.03
Remove
1.Remove rear road wheels.
2.Clean exterior of calipers.
90 Models
110/130 Models
3.Remove pad retaining pins and anti-rattle
springs. Note differences between 90 and
110/130 models.
4.Remove brake pads and shims.
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70BRAKES
12
REPAIR 5.Clean exposed parts of pistons, using new brake
fluid.
6.Wipe away excess fluid with lint free cloth.
7.Using piston clampLRT-70-500press each
piston back into its bore. Ensure that displaced
brake fluid does not overflow from reservoir.
Refit
8.Fit brake pads and shims.
Ensure shims are correctly fitted, see illustration.
NOTE: Vehicles from 02MY have leading
and trailing edge chamfers on rear pads.
Shims are also fitted.
9.Fit anti-rattle springs and secure with retaining
pins.10.Apply service brake pedal several times to locate
pads.
11.Fit road wheels, remove chassis stands and
jack. Tighten wheel nuts to130 Nm (96 lbf/ft).
12.Check fluid reservoir, top up if necessary, using
correct grade of fluid.See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
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77PANEL REPAIRS
8
SEALING AND CORROSION PROTECTION CORROSION PROTECTION
The following information details the materials that are
applied during manufacture for corrosion protection.
Factory Treatments
The Defender is treated with the following
anti-corrosion materials in production:
A PVC-based underbody sealer material
which is sprayed onto the underfloor, wheel
arches and undersill areas.
An application of cavity wax which is
sprayed into enclosed cavities and box
sections.
A final coating of underbody wax to cover
the complete underfloor including
components but excluding brake discs,
exhaust system and propeller shafts.
A coat of protective lacquer applied to the
whole body.
A coat of protective wax applied to the
engine bay and wheel arch areas.
NOTE: Do not apply wax to engine bay of
Td5 models.
In addition to the above measures, all steel parts are
zinc-coated both sides.
Underbody Sealer
Underfloor areas and outer sill panels are treated with
a Plastisol PVC underbody sealer. This material is not
suitable for re-treatment.
When repairing areas of underbody sealer, strip the
factory-applied material back to a suitable break point,
ensuring that a clean metal surface is exposed and
that the edge of the existing material adheres soundly
to the panel.
Blanking plugs and grommets in the floor pan (except
those used for wax injection) MUST be fitted before
underbody sealer application. Heat-fusible plugs
which have been disturbed should either be refitted
with the aid of a hot air blower or replaced with rubber
grommets.
NOTE: Application of new underbody
sealer must be carried out between primer
and surfacer paint operations. Areas
where seam sealer is used should be re-treated as
necessary before application of underbody sealer.
CAUTION: Ensure that suspension units,
wheels, tyres, power unit, driveshafts,
exhaust and brakes (including all
mounting points) are shielded prior to application
of fresh underbody sealer.
Cavity Wax
Cavity wax is applied to certain box sctions The
information given on the following pages is intended
as a guide and shows the areas to be treated with
cavity wax, as well as the access holes used during
manufacture.See GENERAL INFORMATION DATA,
Sealing and corrosion protection section.
Underbody Wax
A coat of underbody wax is applied to the entire
underbody inboard of the sill vertical flanges, and
covers all moving and flexible components EXCEPT
for wheels and tyres, brakes and exhaust. The wax is
applied over paints and underbody sealers.
The underbody wax must be reinstated following all
repairs affecting floor panels.
CAUTION: Old underbody wax must be
completely removed from a zone
extending at least 200 mm (7.9 in) beyond
the area where new underbody sealer is to be
applied.
Engine Bay Wax
Reinstate protective engine bay wax disturbed during
repairs using the approved material.
Wheel Arch Wax
Reinstate protective wheel arch wax disturbed during
repairs using the approved material.
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PANEL REPAIRS
3
REPAIR WHEEL ARCH - FRONT
Remove
The procedure to change the Inner Front Wheelarch is
the same as for the Wing Upper, except for removal of
the ABS sensors and shield, if fitted.
BULKHEAD ASSEMBLY
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove front lower wing.See this Section.
3.Remove RH and LH front upper wing.See this
Section.
4.Remove headlamp mounting panels.See this
Section.
5.Remove screen aperture.See this Section.
6.Remove both front doors.
7.Remove lower fascia panel.See CHASSIS
AND BODY, Repair.
8. Models with A/C:Remove relevant A/C pipes.
9.Remove front grille.
10.Drain cooling system.See COOLING
SYSTEM, Adjustment.
11.Remove radiator and intercooler.
12. Models with A/C:Remove condensor.
13.Remove air cleaner assembly.
14.Remove heater unit.See HEATING AND
VENTILATION, Repair.
15.Remove brake servo assembly.
16.Remove heater ducts.
17.Remove both front seats.
18.Remove front carpets.
19.Release all relevant harnesses and position
aside.
20.Remove facia support bracket.
Refit
21.Prepare and clean panel joint faces. Ensure all
necessary grommets and sealant is applied to
new bulkhead.
22.Reverse removal procedure.
23.Bleed brake system.See BRAKES,
Adjustment.
24.Align headlamps.See ELECTRICAL,
Adjustment.
25.Water test after refitting.
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