warning LAND ROVER DEFENDER 1999 Repair Manual

BRAKES
1
ADJUSTMENT BRAKE SYSTEM BLEED
Service repair no - 70.25.02
Preparation
WARNING: Before bleeding the brake
system refer to general brake service
practice.See this Section. general brake
service practice
During bleed procedure, brake fluid level must
not be allowed to fall below the MIN mark. Keep
reservoir topped up to the MAX mark.
To bleed the hydraulic circuits, four bleed
nipples are provided, one at each caliper.
There are two methods by which air can be removed
from the braking system:-
1.MANUAL BLEED PROCEDURE
2.PRESSURE BLEED PROCEDURE
Pressure bleed procedure
Purpose designed equipment for pressure filling and
bleeding of hydraulic systems may be used on Land
Rover vehicles. The equipment manufacturers
instructions must be followed and the pressure must
not exceed 4.5 bar, 65 lb/in.
Manual bleed procedure
Equipment required
Clean glass receptacle
Bleed hose
Wrench
Approx. 2 litres (3 pts) brake fluid
Master cylinder bleed
1.Disconnect battery negative lead.
2.Depress brake pedal fully and slowly 5 times.
3.Release pedal and wait 10 seconds.
4.Repeat until firm resistance is felt at the pedal.Complete circuit bleed
1.Disconnect battery negative lead.
2.Fit bleed hose to caliper bleed screw.
3.Dip free end of bleed hose into brake fluid in
bleed bottle.
4.Open bleed nipple.
5.Depress brake pedal fully several times until fluid
is clear of air bubbles.
6.Keeping pedal fully depresses, tighten bleed
nipple then release pedal.
7.Repeat procedure for remaining calipers.
8.Fit bleed screw protection caps.
9.Check/top-up fluid level when bleeding is
complete.
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BRAKES
7
REPAIR Refit
11.Position modulator to mounting bracket and
connect multiplug.
12.Fit modulator to mounting bracket and tighten
nuts to9 Nm (7 lbf.ft).
13.Connect 2 multiplugs to rear of modulator.
14.Remove plugs from brake pipes and modulator.
15.Clean brake pipe unions.
16.Connect brake pipe unions to modulator
ensuring pipes are connected to their correct
ports.
17.Tighten all unions to14 Nm (10 lbf.ft).
18.Bleed brake system.See Adjustment.
NOTE: To ensure correct operation, the
ABS system MUST be tested using
TestBook.BRAKE CALIPER - FRONT
Service repair no - 70.55.02
Remove
1.Loosen front road wheel nuts.
2.Raise front of vehicle.
WARNING: Support on safety stands.
3.Remove road wheel.
4.Remove split pins from pad retaining pins.
5.Remove brake pad retainers and springs.
6.Remove brake pads and shim if fitted.
7.Pull back brake hose shield.
8.Clamp brake hose using a suitable clamp.
9.Position container beneath brake caliper to
collect spillage.
10.Loosen brake pipe union and disconnect from
caliper.
11.Plug brake pipe and caliper connections.
12.Remove 2 bolts securing caliper.
13.Remove brake caliper.
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70BRAKES
8
REPAIR Refit
14.Clean caliper to hub mating faces.
15.Position caliper to hub, fit bolts and tighten to82
Nm (60 lbf.ft).
16.Remove plugs from pipe to caliper connections
and wipe.
17.Connect pipe to caliper, tighten union to15 Nm
(11 lbf.ft).
18.Apply a light film of grease to rear of brake pads.
19.Fit pads to calipers.
From 02MY, ensure pads are correctly fitted,
with leading edge chamfer fitted as shown.
20.Fit pad retainers and springs.
21.Fit split pins to retainers.
22.Remove brake hose clamp.
23.Bleed brakes.See Adjustment.
24.Depress brake pedal to seat pads onto discs.
25.Fit road wheels, remove axle stands and tighten
nuts to130 Nm (96 lbf.ft).BRAKE CALIPER - REAR
Service repair no - 70.55.03
Remove
1.Loosen rear road wheel nuts.
2.Raise rear of vehicle.
WARNING: Support on safety stands.
3.Remove road wheel.
4.Remove split pins from brake pad retaining pins.
5.Remove brake pad retaining pins.
6.Remove brake pad retainer springs.
7.Remove brake pads and shim if fitted.
8.Position container beneath brake caliper to
collect spillage.
9.Loosen brake pipe union and disconnect from
caliper.
CAUTION: Plug the connections.
10.Remove 2 bolts securing caliper.
11.Remove brake caliper.
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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
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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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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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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76CHASSIS AND BODY
30
REPAIR Refit
7.Insert glass into channels and carefully push to
top of frame.
8.Secure glass channels with screws. Ensure
screw heads are down below bottom of channels
to prevent damage to glass.
9.Fit inner and outer waist seal to door.
10.Fit check strap.
11.Fit check strap torsion bar and tighten nuts to10
Nm (7 lbf.ft).
12.Fit rear door mounting panel.See this Section.GLASS/SEALING RUBBER - TAIL DOOR - FROM
02MY
Service repair no - 76.31.22
Remove
1.Remove spare wheel from tail door.
2.Raise nut cover, remove nut and release wiper
arm.
3.Open rear door.
4.Remove CHMSL assembly.See
ELECTRICAL, Repair.
5.Disconnect 4 Lucar connections.
6.With assistance, from inside of vehicle apply
pressure to glass, relieve seal lip and carefully
remove glass.
WARNING: Wear suitable eye protection
when removing and refitting glass.
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77PANEL REPAIRS
10
SEALING AND CORROSION PROTECTION Underbody Protection Repairs
When body repairs are carried out, always ensure that
full sealing and corrosion protection treatments are
restored. This applies both to the damaged area, and
also to areas where protection has been indirectly
impaired as a result of accident damage or repair
operations.
Prior to straightening out or panel beating, remove all
corrosion protection material in the damaged area.
This applies in particular to panels coated with wax,
PVC underbody sealer, sound deadening pads etc.
WARNING: DO NOT use oxy-acetylene gas
equipment to remove corrosion prevention
materials. Large amounts of fumes and
gases are liberated by these materials when they
burn.
Equipment for the removal of tough anti-corrosion
sealers offers varying degrees of speed and
effectiveness. The compressed air-operated scraper
(NOT an air chisel) offers a relatively quiet mechanical
method of removal using an extremely rapid
reciprocating action. During use, direct the operating
end of the tool along the work surface.
The most common method is by the use of a hot air
blower with integral scraper.
CAUTION: High temperatures can be
generated with this equipment which may
cause fumes. Always exercise care in its
use.
Another tool, and one of the most efficient methods, is
the rapid-cutting’hot knife’. This tool uses a wide
blade and is quick and versatile, able to be used
easily in profiled sections where access is otherwise
awkward.
Use the following procedure when repairing
underbody coatings:
1.Remove existing underbody coatings.2.After panel repair, clean the affected area with a
solvent wipe, and treat bare metal with an etch
phosphate material.
3.Re-prime the affected area.DO NOT under any
circumstances apply underbody sealer
directly to bare metal surfaces.
4.Replace all heat-fusible plugs which have been
disturbed. Use rubber grommets of equivalent
size if plugs are not available, but ensure that
they are embedded in sealer.
5.Mask off all mounting faces from which
mechanical components, hoses and pipe clips,
have been removed. Underbody sealer must be
appliedbeforesuch components are refitted.
6.Brush sealer into all exposed seams.
7.Spray the affected area with an approved
service underbody sealer.
8.Remove masking from component mating faces,
and touch-in where necessary. Allow adequate
drying time before applying underbody wax.
Underbody Wax
After refitting mechanical components, including
hoses, pipes and small fixtures, mask off the brake
discs and apply a coat of approved underbody wax.
NOTE: Where repairs include the
application of finish paint coats in the
areas requiring underbody wax, paint
operations must be carried out BEFORE wax
application.
Underbonnet Wax
Where repairs have involved replacement of engine
bay panels, treat the entire engine compartment
including all components, clips and small fixtures with
an approved underbonnet lacquer or wax.
Proprietary Anti-Corrosion Treatments
The application of proprietary anti-corrosion
treatments in addition to the factory-applied treatment
could invalidate the Corrosion Warranty and should be
discouraged. This does not apply to approved,
compatible, preservative waxes which may be applied
on top of existing coatings.
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PANEL REPAIRS
1
PROCEDURES GENERAL WELDING PRECAUTIONS
The following pages show the procedures to follow
when using welding for repairs. No resistance spot
welds have been used in any of the repairs.
The Aluminium alloy used on all Defender models is a
combination of Aluminium and Magnesium.
When converting a MIG welder for use on Aluminium
it is essential the following components are changed.
The materials shown in brackets are the correct
materials to use:
Torch liner (Teflon or Carbon Fibre)
Contact tip
Feed rollers/wheels
Correct Filler wire (combination of
Aluminium and Magnesium)
Shielding gas (Argon)
When carrying out welding operations the following
criteria must be observed:
Where resistance spot welds have been
used in production, these must be replaced
with either MIG plug welds or rivets.
To replace each production spot weld an 8
mm (0.31 in) hole must be drilled and/or
punched, and a MIG weld then made in its
place. The number of plug welds must
match exactly the number of spot welds
which have been removed.
Where holes are left in an existing panel
after removal of the spot welds, a single
MIG plug weld will be made in each hole as
appropriate.
When MIG welding ensure the correct wire
is used.
The replacement welds in the welding
diagrams are denoted by the following
symbols:
A. MIG Plug welds
B. MIG seam weld
Seat Belt Anchorages
Seat belt anchorages are safety critical. When making
repairs in these areas it is essential to follow design
specifications.
Where possible, the original production assembly
should be used, complete with its seat belt
anchorages, or the cut line should be so arranged that
the original seatbelt anchorage is not disturbed.
All welds within 250mm (9.9in.) of seat belt
anchorages must be carefully checked for weld
quality, including spacing of spot welds. A crack
detection process must be carried out in these areas.
WARNING: Body parts incorporating seat
belt anchorages MUST be renewed
completely if damaged beyond repair, as
the welds in these areas are safety critical and
cannot be disturbed.
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