LAND ROVER DEFENDER 1999 Workshop Manual

76CHASSIS AND BODY
12
REPAIR SEAT BELT - FRONT
Service repair no - 76.73.13
Remove
1.Remove cap from seat belt guide bolt.
2.Remove bolt securing seat belt guide to’B’post.
3.Release belt from’B’post mounting.
4.Remove 3 bolts securing belt bracket to seat
base.
5.Remove 2 studs securing seat belt retaining clip.
6.Remove retaining clip.
7.Remove bolt securing inertia reel to body.
8.Remove automatic belt assembly.
9.Remove 2 bolts securing stalk to body.
10.Remove stalk.
Refit
11.Position stalk and tighten bolts.
12.Position automatic belt assembly to body and
tighten bolt to38 Nm
13.Unreel portion of belt.
14.Position bracket to seat base, tighten bolts.
15.Position belt to’B’post mounting and tighten bolt
to32 Nm (24 lbf.ft).
16.Fit cap to bolt head.
17.Position belt retaining clip to seat base and
secure with studs.
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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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CHASSIS AND BODY
15
REPAIR COVER - CUSHION - REAR SEAT
Service repair no - 78.40.04
Remove
1.Remove rear seat.See this Section.
2.Remove 2 bolts securing squab to cushion
frame.
3.Remove squab and collect spacer.
4.Remove 17 screws securing base board to seat
cushion frame and remove board.
5.Remove 2 trim retaining clips.
6.Release cover retainers from seat frame.
7.Remove cover from cushion pad.
Refit
8.Position cover to cushion pad and secure
retainers to seat frame.
9.Fit trim retaining clips.
10.Position base board and tighten screws.
11.Position and align squab to cushion frame.
12.Fit spacer and tighten securing bolts.
13.Fit rear seat.See this Section.
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76CHASSIS AND BODY
16
REPAIR COVER - SQUAB - REAR SEAT
Service repair no - 78.90.13
Remove
1.Remove rear seat.See this Section.
2.Remove 2 screws and remove squab striker.
3.Remove 2 bolts securing squab to cushion
frame.
4.Remove squab stop bolt.
5.Remove squab and collect spacer.
6.Release velcro securing squab cover edges and
fold cover over squab pad.
7.Remove squab cover.
Refit
8.Position cover to squab pad, align to its fitted
position and secure velcro.
9.Position and align squab to cushion frame.
10.Fit spacer and tighten securing bolts.
11.Fit and tighten squab stop bolt.
12.Fit squab striker and tighten screws.
13.Fit rear seat.See this Section.REGULATOR - REAR DOOR GLASS
Service repair no - 76.31.46
Remove
1.Remove rear door trim casing.See this
Section.
2.Carefully release plastic sheet from rear door.
3.Remove 2 bolts securing door glass to regulator.
4.Raise glass and secure with a suitable wedge.
5.Remove 4 bolts securing glass regulator
assembly to door.
6.Manoeuvre regulator through access hole at
bottom of the door.
Refit
7.Clean mating face of regulator and door glass.
8.Lubricate regulator with grease.
9.Position regulator in door and secure with bolts.
10.Remove wedge holding glass and align glass to
regulator.
11.Secure glass to regulator and fit and tighten
bolts.
12.Fit plastic sheet to rear door.
13.Fit rear door trim casing.See this Section.
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CHASSIS AND BODY
17
REPAIR TRIM CASING - REAR DOOR
Service repair no - 76.34.04.99
Remove
1.Remove screw securing door handle
escutcheon.
2.Remove escutcheon.
3.Remove interior lock button bezel.
4.Remove retaining clip and remove door glass
regulator handle.
5.Release covers and remove 2 screws securing
door pull to door.
6.Carefully release 12 clips securing trim casing to
door and remove door casing.Refit
7.Fit trim casing to door and secure with clips.
8.Fit door glass regulator handle.
9.Fit escutcheon to door handle and tighten screw.
10.Fit door lock button bezel.
11.Fit door pull and secure with screws.
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76CHASSIS AND BODY
18
REPAIR AUXILLIARY SWITCH PANEL
Service repair no - 76.46.38
Remove
1.Remove 2 screws securing axilliary switch panel
to fascia and collect nuts and washers.
2.Disconnect multiplug from headlamp Levelling
switch.
3.Disconnect multiplug and Lucar from cigar
lighter.
4.Noting their fitted position, disconnect 4 Lucars
from rear wash wipe switch.
5.Remove switch panel.Do not carry out further dismantling if
component is removed for access only.6.Release pin securing rear wash wipe knob to
switch and remove knob.
7.Remove locknut securing rear wash wipe switch
to panel.
8.Remove rear wash wipe switch.
9.Remove knob from headlamp levelling switch.
10.Remove locknut securing headlamp switch to
panel.
11.Remove headlamp levelling switch.
12.Remove element from cigar lighter.
13.Release bulb holder from cigar lighter.
14.Release cigar lighter from tags and remove from
panel.
15.Fit cigar lighter to panel and locate tags.
16.Fit bulb holder to cigar lighter.
17.Fit element to cigar lighter.
18.Fit headlamp levelling switch to panel and
secure with locknut.
19.Fit knob to headlamp levelling switch.
20.Fit rear wash wipe switch to panel and secure
with locknut.
21.Fit knob to rear wash wipe switch, ensuring pin
is correctly located.
Refit
22.Position auxilliary switch panel to fascia and
connect 4 Lucars to rear wash wipe switch.
23.Connect multiplug and Lucar to cigar lighter.
24.Connect multiplug to headlamp levelling switch.
25.Fit auxilliary switch panel to fascia and secure
with screws.
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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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76CHASSIS AND BODY
20
REPAIR
14.Carefully prise Land Rover decal from grab
handle.
15.Remove 2 screws securing grab handle to crash
pad and lower fascia panel.
16.Remove grab handle.
17.Remove 4 screws securing demister vents to
crash pad.
18.Remove both demister vents.
19.Remove 3 screws securing crash pad to
bulkhead.
20.Remove crash pad.
21.Release radio from fascia.
22.Disconnect 2 multiplugs and aerial from radio.23.Remove radio.
24.Remove 2 trim studs securing radio housing to
fascia.
25.Remove radio housing.
26.Remove auxilliary switch panel.See this
Section.
27.Remove auxilliary switch panel cover.
28.Remove interior fuse box cover.
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CHASSIS AND BODY
21
REPAIR
29.Remove 2 screws securing each footwell vent
and remove vents from lower fascia.
30.Remove screw securing each door check strap
cover and remove both covers.
31.Remove 3 screws securing wiper motor cover to
bulkhead.
32.Remove wiper motor cover.
33.Remove 3 screws securing finisher rail to lower
fascia.
34.Remove finisher rail.
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