light LAND ROVER DEFENDER 1999 Service Manual

CHASSIS AND BODY
29
REPAIR 25.Position console and connect Lucar and
multiplug to cigar lighter.
26.Connect multiplugs to remaining switches.
27.Fit console and secure with screws.
28.Fit crash pad and secure with screws.
29.Fit demister vents and secure with screws.
30.Fit grab handle, secure with screws and fit Land
Rover decal.
31.Fit heater control to fascia and secure with
screws.
32.Position instrument pack and connect multiplugs.
33.Fit instrument pack to fascia and secure with
screws.
34.Fit radio.See ELECTRICAL, Repair.
35.Connect battery earth lead.See ELECTRICAL,
Repair.GLASS - REAR DOOR - FROM 02MY
Service repair no - 76.31.02
Remove
1.Remove rear door mounting panel.See this
Section.
2.Loosen 2 nuts and remove door check strap
torsion bar and plate.
3.Remove check strap.
4.Remove inner and outer waist seal.
5.Remove screw from each glass channel.
6.Lower glass to bottom of door, lift over lower
edge and withdraw from door.
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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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PANEL REPAIRS
3
SEALING AND CORROSION PROTECTION DESCRIPTION - USEAGE SUPPLIER PART NUMBER
SEAM SEALERS - continued
Terolan Light Seam Sealer - bolted, spot welded and bonded
panel edges; type (a) and (b) gaps between panels; between
bonded panels; type (c) clinch jointsTeroson
Terolan Special Brushable Seam Sealer - lap joints 12 Teroson
Terostat Sprayable Seam Sealer - bolted, spot welded and
bonded panel edges; between bonded panels; type (a) and
(b) gaps between panelsTeroson 9320
Terostat 1K PU Seam Sealer (SE 20) - type (a) and (b) gaps
between panels; spot welded and bonded panel edgesTeroson
Sealing compound - bolted, spot welded and bonded panel
edges; type (b) gaps between panelsWurths 8901001/-/6
STRUCTURAL ADHESIVES
Automotive Structural Adhesive - between bonded panels;
type 5 and 73M 08122
Two part Structural Epoxy - between bonded and spot
welded panels; type (a) clinch jointsCiba - Geigy XB5106/7
UNDERBODY SEALERS
Body Schutz 3M 08861
Spray Schutz 3M 08877
Crodapol Brushable Sealer Croda PV75
Terotex Underseal (CP02) Teroson 9320
UNDERBODY WAXES
Stone chip coating (smooth) 3M 08158/9
Underbody Wax Croda PW61
Underbody Wax Dinol Tectacote 205
WELD-THROUGH PRIMERS
Weld-thru’coating 3M 05913
Zinc Spray 3M 09113
Zinc Rich Primer ICI P-565 634
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PANEL REPAIRS
5
SEALING AND CORROSION PROTECTION Cooper Pegler Falcon Junior Pneumatic (Airless)
Manufacturer and supplier:
Cooper Pegler & Co. Ltd.
Burgess Hill
Sussex RH15 9LA
Tel. 04 446 42526
Intended primarily for applying transit wax, the Falcon
Junior pneumatic sprayer has a 5-litre (1 gal.)
container with integral hand pump. This high quality
unit provides a simple and effective means of wax
spraying without the need for compressed air or
additional services.
A selection of nozzles, lances and hoses together with
a trigger valve assembly incorporating a filter enable
the sprayer to be used in a variety of applications.
These include general maintenance, wax injection and
paint application. All parts are fully replaceable and
include a wide range of nozzle configurations.
The Falcon Junior is fitted with Viton seals and is
guaranteed for 12 months.3M Application Equipment
Manufacturer:
3M UK PLC
Automotive Trades Group
3M House
PO Box 1
Market Place
Bracknell
Berks. RG12 1JU
Tel. (01344) 858611
All 3M equipment is available from local trade factors
or 3M refinishing factors.
3M Caulking Gun 08002
A lightweight, robust metal skeleton gun designed to
accommodate 325 mm (12.8 in) cartridge for
dispensing sealants etc. This gun facilitates rapid
cartridge loading and features a quick-release lever
for accurate material ejection and cut-off control.
3M Pneumatic Cartridge Gun 08012
An air line fed gun for application of 3M cartridge
products. Excellent ease of application for a smooth
sealant bead, and incorporates a regulator valve for
additional control.
Other 3m applicator equipment available:
3M Pneumatic Applicator Guns
Air line fed gun for application of 3M sachet sealers
(Part No. 08006 for 200 ml (6 fl oz) and 310 ml (9 fl
oz) sachets, and Part No. 08007 for all size sachets
including 600 ml (18 fl oz).
3M Applicator Gun 08190
For application of 3M Structural Adhesive 08120.
3M Inner Cavity Wax Applicator Gun
Features 750 mm (29.6 in) flexible tube and using
1-litre (1.76 pt) canisters, this approved equipment is
available from all 3M refinishing factors.
Other 3m applicator equipment available:
Heavy Duty Manual Gun.
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77PANEL REPAIRS
2
PROCEDURES PANEL REPLACEMENT PROCEDURE
General
This information is designed to explain the basic panel
removal and replacement method. This standard
method may vary slightly from one vehicle to another.
The main criterion in removal and replacement of
body panels is that Land Rover’s original standard is
maintained as far as possible.
All repair processes and procedures shown relate to
Aluminium panels.
Remove Panel
1.Expose resistance spot welds. For those spot
welds which are not obviously visible, use a
rotary drum sander or wire brush fitted to an air
drill, or alternatively a hand held wire brush.
WARNING: Ensure breathing mask and
protective glasses are worn during
operations where Aluminium particles are
removed.
CAUTION: Never use a sanding disc that
has previously been used on steel, as iron
deposits could be left on the surface of the
Aluminium.
NOTE: In wheel arch areas it may be
necessary to soften underbody coating
using a hot air gun, prior to exposing spot
welds.
2.Cut out welds using a cobalt drill.
3.Alternatively use a clamp-type spot weld
remover.
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77PANEL REPAIRS
6
REPAIR CORNER CAPPING
The Corner Capping is not replaced as a single panel.
It is replaced in conjunction with either the Body Side
Lower Panel or Body Side Assembly. The procedure
to replace the Corner Capping is shown in the Body
Side Lower Panel procedure.
BODY SIDE CAPPING
The Body Side Capping is not replaced as a single
panel. It is replaced in conjunction with either the
Body Side Lower Panel or Body Side Assembly. The
procedure to replace the Body Side Capping is shown
in the Body Side Lower Panel procedure.
BODY SIDE REAR - UPPER
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove front, centre and rear sections of
headlining.
3.Release upper edge of front door aperture seal.
4.Release upper edge of rear door aperture seal.
5.Remove fixings from front edge of roof, and
along side being replaced.
6.Release sealant securing front edge of roof.
7.Insert wedges into top of both’B/C’posts. This
will allow access for removal of body side.
8. RH side:Remove tail door.See CHASSIS
AND BODY, Repair.
9.Remove side window.
10.Remove rear sixth light.
11.Remove all bolts securing upper body side.
Refit
12.Prepare and clean panel joint faces.
13.Reverse removal procedure.
NOTE: When refitting, ensure body side
upper is correctly fitted onto location pins.
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PANEL REPAIRS
9
REPAIR REAR LAMP PANEL
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect alternator.
3.Remove rear bench seat.
4. RH side:Remove tail door.See CHASSIS
AND BODY, Repair.
5.Remove rear lights and reflector.
6. LH side:Remove number plate and tail door
striker.
Refit
7.Prepare and clean panel joint faces.
8.Reverse removal procedure.REAR CROSSMEMBER PANEL
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove both rear lamp panels.See this
Section.
Refit
3.Prepare and clean panel joint faces.
4.Reverse removal procedure.
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86 - ELECTRICAL
CONTENTS
Page
DESCRIPTION AND OPERATION
SECURITY AND CENTRAL DOOR LOCKING 1....................................................
SECURITY AND CENTRAL DOOR LOCKING 2....................................................
ANTI-THEFT ALARM - FROM 02MY 3...................................................................
IMMOBILISATION SYSTEM - FROM 02MY 12......................................................
CENTRAL DOOR LOCKING (CDL) - FROM 02MY 15...........................................
ANTI-THEFT ALARM SYSTEM SELF TEST 17.....................................................
FASCIA CONSOLE 18............................................................................................
HEATED FRONT SCREEN - FROM 02MY 20.......................................................
HEATED FRONT SEATS - FROM 02MY 22..........................................................
ELECTRIC FRONT WINDOWS - FROM 02MY 24.................................................
PASSENGER COMPARTMENT FUSE BOX 26.....................................................
UNDER SEAT FUSE BOX 27.................................................................................
ADJUSTMENT
HEADLAMPS - ALIGN BEAM 1..............................................................................
SOLENOID/MOTOR - FRONT DOOR - ADJUST 1................................................
REPAIR
BELT - AUXILLARY DRIVE 1.................................................................................
HARNESS - INJECTORS 1....................................................................................
STARTER MOTOR 2..............................................................................................
CENTRE HIGH MOUNTED STOP LIGHT (CHMSL) - UP TO 02MY 2...................
ALTERNATOR 3.....................................................................................................
HORN - LH 4...........................................................................................................
HEADLAMP 5.........................................................................................................
LAMP - TAIL 6.........................................................................................................
RADIO6 ..................................................................................................................
SPEAKER - FRONT 7.............................................................................................
SWITCH - TRANSMISSION BRAKE 7...................................................................
LAMP - FRONT FLASHER 8..................................................................................
BATTERY - DISCONNECT - FROM 02MY 8..........................................................
MOTOR & REGULATOR - FRONT DOOR - FROM 02MY 9..................................
SWITCH - FASCIA - FROM 02MY 10.....................................................................
HARNESS - FRONT DOOR - FROM 02MY 10.......................................................
SOLENOID/MOTOR - TAIL DOOR - FROM 02MY 11............................................
SOLENOID/MOTOR - FRONT DOOR - FROM 02MY 12.......................................
SOLENOID/MOTOR - REAR DOOR - FROM 02MY 13.........................................
HARNESS - REAR DOOR - FROM 02MY 14.........................................................
REVERSE AND FOG GUARD LAMP - BULB 15....................................................
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86 - ELECTRICAL
CONTENTS
Page
LAMP ASSEMBLY - CENTRE HIGH MOUNTED STOP LIGHT (CHMSL) -
FROM 02MY 16......................................................................................................
FLASHER UNIT - HAZARD WARNING - FROM 02MY 16.....................................
RELAY - HEATED FRONT SCREEN - FROM 02MY 17........................................
RELAY - REAR FOG GUARD - FROM 02MY 18...................................................
RELAY - STARTER - FROM 02MY 19...................................................................
SWITCH - HEADLAMP LEVELLING - FROM 02MY 19.........................................
CIGAR LIGHTER - FRONT - FROM 02MY 20........................................................
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86ELECTRICAL
18
DESCRIPTION AND OPERATION FASCIA CONSOLE
1.Rear fog lamp switch
2.Rear wiper switch
3.Heated front screen switch (if fitted)
4.Hazard warning lamp switch
5.Heated rear window switch
6.Rear washer switch
7.Front fog lamps switch (if fitted)8.RH front window switch
9.RH heated front seat switch (if fitted)
10.Headlamp levelling control switch
11.Cigar lighter (if fitted)
12.LH heated front seat switch (if fitted)
13.LH front window switch
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