LAND ROVER DEFENDER 1999 Workshop Manual

76CHASSIS AND BODY
2
REPAIR TRIM CASING - TAIL DOOR - UP TO 02MY
Service repair no - 76.34.09
Remove
1.Remove 2 bolts securing grab handle to tail
door.
2.Remove grab handle.
3.Remove 2 screws securing wiper motor cover.
4.Remove wiper motor cover.
5.Remove 7 screws securing trim casing to door.
6.Remove 2 screws securing wiper motor harness
cover.
7.Remove harness cover.
8.Release 7 of 8 trim studs securing trim casing.
9.Remove trim casing from remaining stud.
10.Collect door lock cover.Refit
11.Position door lock cover.
12.Position trim casing and secure trim casing.
13.Position harness cover and secure with screws.
14.Secure trim pad with screws.
15.Fit wiper motor cover and secure with screws.
16.Fit grab handle and secure with screws.
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CHASSIS AND BODY
3
REPAIR LATCH - TAIL DOOR - UP TO 02MY
Service repair no - 76.37.16
Remove
1.Remove tail door trim casing.See this Section.
2.Collect latch cover.
3.Remove 2 screws securing latch to door and
collect captive nut bracket.
4.Remove 2 nuts securing latch to door and collect
captive bolt bracket.
5.Remove latch assembly and collect foam
gasket.
Refit
6.Fit foam gasket and latch assembly to tail door.
7.Fit captive nut and bolt brackets to tail door.
8.Secure latch to tail door with nuts and screws.
9.Fit cover to latch.
10.Fit tail door trim casing.See this Section.CARPET - LUGGAGE COMPARTMENT
Service repair no - 76.49.04
Remove
1.Remove 7 screws and remove carpet retainer.
2.Remove bolt covers and remove rear seat belt
bolts.
3.Release rear seat catches and fold seats
forward.
4.Remove luggage compartment carpet.
Refit
5.Position carpet.
6.Fold rear seats to position.
7.Align rear seat belts and tighten tighten bolts.
8.Fit bolt covers.
9.Position carpet retainer and tighten screws.
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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
5
REPAIR
13.Remove 4 bolts securing radiator mounting
bracket to wing.
14.Loosen screw and release bonnet lock inner
cable from bonnet lock.
15.Release bonnet lock outer cable from from
bonnet lock.
16.Push centre pins from studs securing wheel arch
extension to wing, remove studs and remove
wheel arch extension.
17.Remove bolt securing inner and outer wing to
chassis.
18.Remove nut and bolt securing support stay to
wing.
19.Remove 4 bolts securing wing to’A’post.
20.Remove bolt securing wing to bulkhead.
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76CHASSIS AND BODY
6
REPAIR
21.Disconnect headlamp, side lamp, repeater and
indicator multiplugs.
22.With assistance, remove wing.
23.Remove bolt, remove grille support bracket.
24.Remove 4 screws securing side and indicator
lamps.
25.Remove 2 screws securing headlamp finisher to
wing, remove finisher.
26.Remove 4 screws and remove headlamp from
wing, collect sealing ring.
27.Release side repeater lamp from wing.
28.Remove bonnet cable grommet.
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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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