LAND ROVER DEFENDER 1999 Workshop Manual

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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76 - CHASSIS AND BODY
CONTENTS
Page
DESCRIPTION AND OPERATION
FRONT SEAT RECLINE - FROM 02MY 1..............................................................
SOFT TOP - FROM 02MY 1...................................................................................
TAIL DOOR - FROM 02MY 2..................................................................................
ADJUSTMENT
TAIL DOOR STRIKER 1.........................................................................................
REPAIR
PANEL - UNDERBELLY - FRONT AND CENTRE 1...............................................
CUBBY BOX 1........................................................................................................
TRIM CASING - TAIL DOOR - UP TO 02MY 2.......................................................
LATCH - TAIL DOOR - UP TO 02MY 3..................................................................
CARPET - LUGGAGE COMPARTMENT 3.............................................................
WING - FRONT 4....................................................................................................
STEP - FOLDING - REAR DOOR 7........................................................................
LINER - FRONT WHEEL ARCH 8..........................................................................
FRONT BUMPER 9.................................................................................................
DOOR - REAR 9.....................................................................................................
DOOR - TAIL - REMOVE 10...................................................................................
GLASS/SEALING RUBBER - TAIL DOOR - UP TO 02MY 11................................
SEAT BELT - FRONT 12........................................................................................
SEAT BELT - CENTRE - REAR 13.........................................................................
SEAT BELT - REAR - SIDE 13...............................................................................
SEAT - REAR 14.....................................................................................................
COVER - CUSHION - REAR SEAT 15...................................................................
COVER - SQUAB - REAR SEAT 16.......................................................................
REGULATOR - REAR DOOR GLASS 16...............................................................
TRIM CASING - REAR DOOR 17...........................................................................
AUXILLIARY SWITCH PANEL 18...........................................................................
LOWER FASCIA PANEL - UP TO 02MY 19...........................................................
PANEL - MOUNTING - FRONT DOOR - FROM 02MY 23.....................................
PANEL - MOUNTING - REAR DOOR - FROM 02MY 25........................................
FACIA CONSOLE - FROM 02MY 27......................................................................
GLASS - REAR DOOR - FROM 02MY 29..............................................................
GLASS/SEALING RUBBER - TAIL DOOR - FROM 02MY 30................................
TRIM CASING - FRONT DOOR - FROM 02MY 31................................................
TRIM CASING - TAIL DOOR - FROM 02MY 33.....................................................
PLASTIC SHEET - FRONT DOOR - FROM 02MY 34............................................
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76 - CHASSIS AND BODY
CONTENTS
Page
PLASTIC SHEET - REAR DOOR - FROM 02MY 34..............................................
LOCK - TAIL DOOR - FROM 02MY 35...................................................................
LOWER FASCIA PANEL - FROM 02MY 36...........................................................
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CHASSIS AND BODY
1
DESCRIPTION AND OPERATION FRONT SEAT RECLINE - FROM 02MY
Front seat recline has been improved by removing the bulkhead situated behind the front seats. This enables the
front seats to be reclined further than previous Defender 90’s.
This change is only applicable to 90 County Station Wagon models. Six seat derivatives of this model will provide
greater incline of the front seats and increased cabin space.
SOFT TOP - FROM 02MY
The soft top is replaced by an improved version manufactured from PVC. The PVC soft top gives the following
improvements:
Resistance to shrinkage
No zips
Resistant to dust and water ingress
Weld seams and joints
Non cotton base construction
Easy to clean
Beach Bar
A beach bar, currently used on military vehicles only, will be introduced for fitment on all 02MY soft top vehicles.
The bar is located behind the front seats and is manufactured from large diameter steel tubing with a diagonal bar
which gives additional rigidity.
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76CHASSIS AND BODY
2
DESCRIPTION AND OPERATION TAIL DOOR - FROM 02MY
1.Rubber window seal
2.CHMSL earth connection
3.CHMSL
4.Tail door glass and HRW element
5.Tail door CDL actuator
6.Rear wiper relay
7.Wiper motor
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CHASSIS AND BODY
3
DESCRIPTION AND OPERATION The tail door for 02MY is completely redesigned to address manufacturing complexity, corrosion and water ingress
probelms on previous tail doors.
The tail door is now a one piece outer skin pressing located on a reinforced steel, zinc plated frame. This gives
improved build quality, water integrity and minimal welding.
A new tail door glass is introduced with a one piece continuous rubber seal. The tail door glass has a revised
Heated Rear Window (HRW) element on the glass which removes the need to route wires up the sides of the
frame. The HRW element now has integral Lucar connections in the element which provide the earth connections
for the new centre high mounted stop lamp.
The inner trim panel is new and accommodates the CDL actuator and linkages.
The new tail door also contains a relay for rear wiper motor operation. Refer to the Wipers section for details.
Because the new tail door uses the current hinges and latch and retains the same geometry as the previous tail
door, the new tail door assembly is available as a service item for current vehicles.
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CHASSIS AND BODY
1
ADJUSTMENT TAIL DOOR STRIKER
Service repair no - 76.37.25
Check
1.Before adjusting door striker, ensure spare
wheel is fitted to tail door.
Adjust
1.Loosen bolts securing striker.
2.Adjust striker and tighten bolts to10 Nm (7
lbf.ft).
3.Close door and check for correct latching.
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CHASSIS AND BODY
1
REPAIR PANEL - UNDERBELLY - FRONT AND CENTRE
Service repair no - 76.10.50
Remove
1.Raise vehicle on 4 post ramp.
2.Mark front propellor shaft and front differential
flanges for reassembly.
3.Remove 4 bolts and release propellor shaft from
front differential.
4.Remove 12 bolts securing front and centre
underbelly panels.
5.Remove front and centre underbelly panels.
Refit
6.Position front and centre underbelly panels.
7.Fit and tighten bolts securing front and centre
underbelly panels.
8.Position front propellor shaft to differential and
tighten bolts to48 Nm (35 lbf.ft).
9.Lower vehicle.CUBBY BOX
Service repair no - 76.25.04
Remove
1.Open cubby box lid and remove 2 caps
concealing rear fixing bolts.
2.Remove bolts securing rear of cubby box.
3.Open flap concealing front fixing bolts.
4.Remove bolts securing front of cubby box.
5.Remove cubby box.
Refit
6.Fit cubby box to vehicle.
7.Fit bolts securing front of cubby box and
reposition flap.
8.Fit bolts securing rear of cubby box.
9.Fit caps over bolts.
10.Close cubby box lid.
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