battery LAND ROVER DEFENDER 1999 Repair Manual
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 1999, Model line: DEFENDER, Model: LAND ROVER DEFENDER 1999Pages: 667, PDF Size: 8.76 MB
Page 453 of 667
70BRAKES
4
REPAIR MASTER CYLINDER
Service repair no - 70.30.08
Remove
1.Disconnect battery negative lead.
2.Place a container under the master cylinder to
collect any brake fluid spillage.
CAUTION: Do not allow brake fluid to
contact paint finished surfaces as paint
may be damaged. If spilled, remove fluid
and clean area with clean warm water.
3.Clean area around master cylinder ports.
4.Loosen 2 unions securing brake pipes to master
cylinder ports.
5.Disconnect both brake pipes from master
cylinder. Cover, not plug, pipe ends to prevent
entry of dirt.
6.Disconnect 2 Lucars from reservoir cap.
7.Remove 2 nuts securing master cylinder to
brake servo.
8.Withdraw master cylinder from servo and
remove.
Do not carry out further dismantling if
component is removed for access only.9.Carefully ease reservoir from master cylinder by
rolling it from seals.
10.Remove seals from master cylinder.
NOTE: Master cylinder to reservoir seals
are different sizes.
11.Fit NEW seals to master cylinder, ensuring seals
are fitted to correct ports.
12.Fit reservoir to master cylinder.
Refit
13.Ensuring that water ingress seal is in position, fit
master cylinder to servo.
14.Fit nuts securing master cylinder to servo and
tighten to26 Nm (19 lbf.ft).
15.Connect brake pipes to master cylinder and
tighten unions to15 Nm (11 lbf.ft).
16.Connect Lucars to reservoir cap.
17.Fill reservoir with recommended brake fluid.See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
18.Bleed the brake system.See Adjustment.
19.Reconnect battery negative lead.
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Page 488 of 667
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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Page 492 of 667
CHASSIS AND BODY
23
REPAIR 59.Fit radio housing to fascia and secure with trim
studs.
60.Position radio to fascia and connect multiplugs
and aerial.
61.Fit radio to fascia.
62.Fit crash pad to fascia and secure with screws.
63.Fit both demister vents to crash pad and secure
with screws.
64.Fit grab handle to fascia and secure with screws.
65.Fit Land Rover decal to grab handle.
66.Position both front speakers to fascia and
connect multiplugs.
67.Fit speakers to fascia and secure with screws.
68.Fit locking rings to speakers.
69.Connect multiplugs and Lucars to HRW, Rear
Fog Guard Lamp, and Hazard Warning
Switches.
70.Fit switches to fascia.
71.Position heater controls to fascia and secure
with screws.
72.Fit instrument pack.See ELECTRICAL,
Repair.
73.Fit 2 halves of nacelle to steering column and
secure with screws.
74.Fit steering wheel.See STEERING, Repair.
75.Reconnect battery negative lead.PANEL - MOUNTING - FRONT DOOR - FROM 02MY
Service repair no - 76.11.28
Remove
1.Remove plastic sheet.See this Section.
2.Lower glass and remove 2 bolts securing door
glass to regulator.
3.Release glass from regulator, raise and wedge
in raised position.
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Page 496 of 667
CHASSIS AND BODY
27
REPAIR FACIA CONSOLE - FROM 02MY
Service repair no - 76.25.03
Remove
1.Disconnect battery earth lead.See
ELECTRICAL, Repair.
2.Remove radio.See ELECTRICAL, Repair.
3.Remove 4 screws securing instrument pack and
release pack from fascia.
4.Disconnect 2 multiplugs from warning lamp
panel.
5.Disconnect instrument pack multiplug from main
harness.
6.Remove instrument pack.
7.Remove 3 screws securing heater control and
release control from fascia.
8.Carefully prise Land Rover decal from grab
handle.
9.Remove 2 screws securing grab handle and
remove handle.
10.Remove 4 screws and remove demister vents.
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Page 498 of 667
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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Page 505 of 667
76CHASSIS AND BODY
36
REPAIR LOWER FASCIA PANEL - FROM 02MY
Service repair no - 76.46.05
Service repair no - 80.10.12
NOTE: This procedure also covers
removal of the air distribution control
cable, 80.10.12.
Remove
1.Disconnect battery negative lead.See
ELECTRICAL, Repair.
2.Remove steering column nacelle.See
STEERING, Repair.
3.Remove fascia console.See this Section.
4.Remove air vent control knobs.
5.Remove 6 screws, remove fascia closing panel
and collect nut plate.
6.Remove speakers.See ELECTRICAL, Repair.
7.Remove 2 screws and remove both door check
strap covers.
8.Remove 3 screws and remove end cap from
lower fascia panel.
9.Loosen grub screw and clamp plate bolt
securing air distribution cable. Release cable
from control lever.
10.Release screen demister tubes from lower fascia
panel.
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Page 506 of 667
CHASSIS AND BODY
37
REPAIR
11.Remove 2 screws securing fuse cover and
remove cover.
12.Remove 7 screws securing lower edge of fascia
panel.
13.Remove footwell cover retaining plates.
14.Remove 2 nuts and remove lower fascia panel.
NOTE: Do not carry out further
dismantling if component is removed for
access only.
15.Remove 21 screws and release air duct cover.
16.Loosen trunnion screw, remove air distribution
cable and duct cover.Refit
17.Fit air distribution cable to duct cover and fit
inner cable to vent flap trunnion.
18.Tighten vent flap trunnion screw to6Nm(4
lbf.ft)and bend cable end to secure.
19.Fit duct cover to lower fascia and fit and tighten
screws.
20.Check condition of seal between heater and
lower fascia, if damaged replace.
21.Carefully fit lower fascia panel and ensure
harness route is correct.
22.Secure lower fascia panel with screws and
tighten nuts to10 Nm (7 lbf.ft).
23.Fit fuse cover and secure with screws.
24.Connect demister tubes to lower fascia panel.
25.Raise air distribution lever to screen demist
position and close footwell vent.
26.Connect air distribution cable to lever, tighten
grub screw and outer cable clamp.
27.Fit end cap to fascia and secure with screws.
28.Fit check strap covers and secure with screws.
29.Fit speakers.See ELECTRICAL, Repair.
30.Fit fascia closing panel.
31.Fit nut plate and fit screws to secure nut plate
and closing panel.
32.Fit knobs to air vent control levers.
33.Fit fascia console.See this Section.
34.Fit steering column nacelle.See STEERING,
Repair.
35.Connect battery negative lead.See
ELECTRICAL, Repair.
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Page 553 of 667
77PANEL REPAIRS
28
SEALING AND CORROSION PROTECTION WATER LEAKS
Sealing charts in this section show those areas of the
bodyshell most likely to be affected by accident
damage and water leaks, and which could therefore
require re-treatment in repair. They do not show those
joint areas which only apply to factory assembly
operations and which are unlikely to be disturbed in
service (e.g. centre tunnel), or where the damage
would be so severe that the entire bodyshell would
normally be written off.
When water leakage occurs, always adopt a logical
approach to the problem using a combination of skill,
experience and intuition. Do not attempt to reach a
conclusion based only on visual evidence, such as
assuming that a leak emanates from the windscreen
because the footwell is wet. It will often be found that
the source of the leak is elsewhere. The correct
procedure will increase the chance of locating a leak,
however obscure it may seem.
Tools and Equipment
The following tools and equipment are recommended
for detection and rectification of water leaks:
1. Garden sprayer (hand-operated).
2. Wet/dry vacuum cleaner.
3. Dry absorbent cloths.
4. Battery torch.
5. Small mirror.
6. Weatherstrip locating tool.
7. Trim panel remover.
8. Small wooden or plastic wedges.
9. Dry compressed air supply.
10. Hot air blower.
11. Sealer applicators.
12. Ultrasonic leak detector.
During leak detection, the vehicle should be
considered in three basic sections:
The front interior space,
The rear passenger space (where
applicable), and
The rear loadspace or boot.Testing
From the information supplied by the customer it
should be possible for the bodyshop operator to locate
the starting point from which the leak may be
detected. After the area of the leak has been
identified, find the actual point of entry into the vehicle.
A simple and effective means initially is an ordinary
garden spray with provision for pressure and jet
adjustment. This will allow water to be directed in a jet
or turned into a fine spray. Use a mirror and a
battery-powered torch (NOT a mains voltage
inspection lamp) to see into dark corners.
The sequence of testing is particularly important. Start
at the lowest point and work slowly upwards, to avoid
testing in one area while masking the leak in another.
For example, if testing started at the level of the
windscreen, any water cascading into the plenum
chamber could leak through a bulkhead grommet and
into the footwells. Even at this point it could still be
wrongly assumed that the windscreen seal was at
fault.
Another important part of identifying a water leak is by
visual examination of door aperture seals, grommets
and weatherstrips for damage, deterioration or
misalignment, together with the fit of the door itself
against the seals.
Sealing
When the point of the leak has been detected,
proceed to rectify it using the following procedure:
1. Renew all door aperture seals and weatherstrips
which have suffered damage, misalignment or
deterioration.
2. Check all body seals to ensure that they are
correctly located on their mounting flanges/faces
using a locating tool if necessary.
3. Dry out body seams to be treated using
compressed air and/or a hot air blower as
necessary.
4. Apply sealant on the outside of the joint
wherever possible to ensure the exclusion of
water.
5. When rectifying leaks between a screen glass
and its weatherstrip (or in the case of direct
glazing, between the glass and bodywork), avoid
removing the glass if possible. Apply the
approved material either at the glass to
weatherstrip or glass to body.
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Page 566 of 667
PANEL REPAIRS
1
REPAIR WING LOWER FRONT
Remove
1.Disconnect both battery leads, negative lead
first. system.
2.Remove wheel arch eyebrow.
3.Remove wheel arch liner.
4. RH side:Remove aerial.
5.Remove air intake hose.
6.Remove bolts securing lower wing.
Refit
7.Prepare and clean panel joint faces.
8.Reverse removal procedure.HEADLAMP MOUNTING PANEL
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect all ECUs.
3.Remove radiator.See COOLING SYSTEM,
Repair.
4.Recover refrigerant from A/C system.See AIR
CONDITIONING, Repair.
5.Remove headlamp.See ELECTRICAL,
Repair.
6. LH side:Remove screen washer bottle.See
WIPERS AND WASHERS, Repair.
7. RH side:Position PAS reservoir aside.
8.Remove bolts and release welds securing panel,
remove panel.
Refit
9.Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding as
shown.
10.Reverse removal procedure.
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Page 567 of 667
77PANEL REPAIRS
2
REPAIR WING UPPER - LH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove headlamp.See ELECTRICAL,
Repair.
3.Remove headlamp mounting panel.See this
Section.
4.Remove radiator.See COOLING SYSTEM,
Repair.
5.Recover refrigerant from A/C system.See AIR
CONDITIONING, Repair.
6.Remove receiver drier.See AIR
CONDITIONING, Repair.
7.Remove relevant A/C pipes.
8.Remove relevant heater intake pipes.
9.Remove screen washer bottle.
10.Remove wheel arch liner.See CHASSIS AND
BODY, Repair.
11.Remove bolts and release welds securing panel,
remove panel.
Refit
12.Prepare and clean panel joint faces.
13.Reverse removal procedure.
14.Align headlamps.See ELECTRICAL,
Adjustment.WING UPPER - RH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove headlamp.See ELECTRICAL,
Repair.
3.Remove headlamp mounting panel.See this
Section.
4.Remove radiator.See COOLING SYSTEM,
Repair.
5.Recover refrigerant from A/C system.See AIR
CONDITIONING, Repair.
6.Remove relevant A/C pipes.
7.Position PAS reservoir aside.
8.Remove wheel arch liner.See CHASSIS AND
BODY, Repair.
9.Remove aerial.
10.Remove vacuum solenoid valve.
11.Release clips securing coolant reservoir.
12.Remove bolts and release welds securing panel,
remove panel.
Refit13.Prepare and clean panel joint faces.
NOTE: LH panel shown
14.Reverse removal procedure.
15.Align headlamps.See ELECTRICAL,
Adjustment.
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