headlamp LAND ROVER DEFENDER 1999 Workshop Manual

GENERAL SPECIFICATION DATA
9
INFORMATION BULBS
REPLACEMENT BULBS TYPE
Headlamps 12V 60/55W Halogen
Front side lamps 12V 5W
Side repeater lamps 12V 5W
Tail lamps 12V 21W
Cente High Mounted Stop Lamp 12V 21W
Direction indicator lamps 12V 21W
Number plate lamp 12V 4W
Reverse lamp 12V 21W
Rear fog guard lamp 12V 21W
Interior roof lamps 12V 10W
Instrument illumination 12V 1.2W
Warning light panel 12V 1.2W
Hazard warning switch 12V 1.2W
CAUTION: The fitting of new bulbs with wattages in excess of those specified will result in damage
to vehicle wiring and switches.
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10 - MAINTENANCE
CONTENTS
Page
MAINTENANCE
UNDERBONNET VIEW - Td5 1..............................................................................
SEATS AND SEAT BELTS 2..................................................................................
LAMPS, HORNS AND WARNING INDICATORS 2................................................
WIPERS AND WASHERS 3...................................................................................
HANDBRAKE 3.......................................................................................................
BATTERY CONDITION - Td5 4..............................................................................
HANDSET BATTERY 5...........................................................................................
HEADLAMP ALIGNMENT 5....................................................................................
ROAD WHEELS 6...................................................................................................
TYRE PRESSURES, CONDITION AND TREAD DEPTH 6....................................
BRAKE PADS, CALIPERS AND DISCS 7..............................................................
ROAD WHEEL SPEED SENSOR HARNESS - Td5 7............................................
FUEL FILTER ELEMENT 8.....................................................................................
FUEL FILTER SEDIMENTER - Td5 8.....................................................................
INTERCOOLER / COOLING SYSTEM 9................................................................
AMBIENT AIR PRESSURE (AAP) SENSOR - Td5 9..............................................
DOOR LOCKS AND HINGES 10............................................................................
ENGINE COOLANT 10...........................................................................................
BRAKE FLUID 11....................................................................................................
AIR FILTER ELEMENT AND DUMP VALVE 11.....................................................
AUXILIARY DRIVE BELT 12...................................................................................
PAS FLUID, CLUTCH FLUID AND SCREEN WASHER LEVELS 12.....................
STEERING BOX 13................................................................................................
ENGINE OIL 14.......................................................................................................
CENTRIFUGE ROTOR - Td5 14.............................................................................
FULL FLOW OIL FILTER 15...................................................................................
GEARBOX OIL 15...................................................................................................
TRANSFER BOX OIL 16.........................................................................................
FRONT AND REAR AXLE OIL 17..........................................................................
PROPELLER SHAFTS 18.......................................................................................
CLUTCH PIPES AND UNIONS 18..........................................................................
PAS PIPES AND UNIONS 19.................................................................................
ENGINE, GEARBOX, TRANSFER BOX AND AXLES 19.......................................
EXHAUST SYSTEM 20...........................................................................................
STEERING BOX AND SUSPENSION 20...............................................................
STEERING BALL JOINTS 21.................................................................................
SHOCK ABSORBERS 22.......................................................................................
TOWING BRACKET 22...........................................................................................
ENGINE AND TRANSMISSION MOUNTINGS 23..................................................
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10MAINTENANCE
2
MAINTENANCE SEATS AND SEAT BELTS
1.Check seat frames are secured to floor and
show no signs of movement.
2.Check operation of seat slide and tilt
mechanisms, ensuring there is no excessive
play between seat cushion and seat back.
3.Check tightness of accessible seat fixings.
4.Fully extract seat belt and allow it to return under
its own recoil mechanism.
5.Check entire length of seat belt webbing for
signs of fraying or damage. Repeat for all belts.
6.Check security of seat belt upper mountings.
7.Check security of seat belt buckle mountings.
8.Connect each belt to the correct buckle, check
seat belt buckle and tongue are secure. Release
seat belt buckle and check for correct operation.
9.Check tightness of accessible seat belt
mountingsLAMPS, HORNS AND WARNING INDICATORS
1.Switch on side, head and tail lights and check
operation.
2.Check headlamp dim/dip operation.
3.Check headlamp levelling operation.
4.Check turn signals and hazard warning lights
operation.
5.Press brake pedal and check operation of brake
lights.
6.Check all exterior lamp lenses for clarity and
condition. Pay particular attention to head lamp
lenses for signs of stone chips or damage.
7.Check horn for loud clear sound.
8.Check operation of all instrument pack warning
and indicator lights.
9.Check for correct operation of interior courtesy
lights.
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MAINTENANCE
5
MAINTENANCE HANDSET BATTERY
Remove
NOTE: Do not remove a battery until you
are ready to install the replacement.
Always fit a Land Rover STC4080 or a
Panasonic CR2032 replacement battery.
1.Unlock the vehicle and disarm the alarm system.
2.Turn the ignition switch to position’II’, then turn
to position’0’and remove the key.
3.Carefully prise the handset apart, starting from
the keyring end. Avoid damaging the seal
between the two halves of the case.
CAUTION: Do not allow moisture to get
inside the handset.
4.Slide the battery out of its clip, taking care to
avoid touching the circuit board or the contact
surfaces of the clip.
5.Press and hold one of the buttons for at least 5
seconds to drain any residual power from the
handset.
Refit
6.Fit the new battery, ensuring that correct polarity
is maintained (+ve side facing up). Finger marks
will adversely affect battery life. Avoid touching
the flat surfaces of the battery, and wipe clean
before fitment.
7.Reassemble the two halves of the handset.
Operate the Padlock symbol button at least 4
times within range of the vehicle to
resynchronise the hanset.HEADLAMP ALIGNMENT
1.Check alignment of headlamps.See
ELECTRICAL, Adjustment.
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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
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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77 - PANEL REPAIRS
CONTENTS
Page
INFORMATION
BODY REPAIRS 1..................................................................................................
ELECTRONIC CONTROL UNITS (ECU’s) 3..........................................................
BODY DIMENSIONS
CHASSIS AND BODY 1..........................................................................................
CHASSIS FRAME ALIGNMENT 2..........................................................................
GAP AND PROFILE INFORMATION 9...................................................................
SEALING AND CORROSION PROTECTION
APPROVED MATERIALS 1....................................................................................
APPLICATION EQUIPMENT 4...............................................................................
CORROSION PROTECTION 8...............................................................................
CAVITY WAX 12.....................................................................................................
SEALANTS AND ADHESIVES 17..........................................................................
WATER LEAKS 28..................................................................................................
PANELS
SERVICEABLE PANELS 1.....................................................................................
PROCEDURES
GENERAL WELDING PRECAUTIONS 1...............................................................
PANEL REPLACEMENT PROCEDURE 2..............................................................
REPAIR PROCEDURES 6......................................................................................
REPAIR
WING LOWER FRONT 1........................................................................................
HEADLAMP MOUNTING PANEL 1........................................................................
WING UPPER - LH 2..............................................................................................
WING UPPER - RH 2..............................................................................................
WHEEL ARCH - FRONT 3......................................................................................
BULKHEAD ASSEMBLY 3......................................................................................
SCREEN APERTURE 4..........................................................................................
SILL - FRONT 5......................................................................................................
’B/C’&’D’POST 5..................................................................................................
CORNER CAPPING 6.............................................................................................
BODY SIDE CAPPING 6.........................................................................................
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77PANEL REPAIRS
2
PANELS
4.Headlamp mounting panel - inner
5.Headlamp mounting panel - outer
6.Wing upper
7.Headlamp reinforcement panel
8.Wing lower
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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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