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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual
Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual
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76CHASSIS AND BODY 22 REPAIR 35.Remove 7 trim clips securing trim upper fascia trim casing to bulkhead. 36.Carefully fold back trim casing over fresh air vent operating levers and remove. 37.Release demist hose from parcel shelf. 38.Remove 18 screws securing parcel shelf to lower fascia panel. 39.Remove parcel shelf. 40.Remove 7 screws securing bottom edge of lower fascia panel to bulkhead. 41.Remove both retaining plates and lower footwell covers. 42.Remove 2 bolts securing top of lower fascia to bulkhead. 43.With assistance, remove lower fascia.Refit 44.With assistance, fit lower fascia. 45.Fit 2 bolts securing top of lower fascia to bulkhead. 46.Fit both retaining plates and footwell covers to lower fascia. 47.Fit 7 screws securing bottom edge of lower fascia to bulkhead. 48.Fit parcel shelf to lower fascia and secure with screws. 49.Fit demist hose to parcel shelf. 50.Carefully manoeuvre upper fascia trim casing over fresh air vents and fit to fascia. 51.Fit trim clips securing trim casing to bulkhead. 52.Fit finisher rail to lower fascia and secure with screws. 53.Fit wiper motor cover and secure with screws. 54.Fit both door check strap covers and secure with screws. 55.Fit both footwell vents to lower fascia and secure with screws. 56.Fit interior fuse box cover. 57.Fit auxilliary switch panel cover. 58.Fit auxilliary switch panel.See this Section.
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.
76CHASSIS AND BODY 24 REPAIR 4.Release clip, detach and remove lock solenoid link. 5.Loosen 2 screws securing solenoid, release solenoid from mounting panel, disconnect multiplug and remove solenoid. 6.Release clip and disconnect interior handle link from latch mechanism.7.Release clips securing harness to panel. 8.Disconnect multiplug from motor. 9.Release harness sleeve and withdraw harness from door. 10.Remove 6 bolts and 1 nut securing panel. 11.Remove panel assembly.
CHASSIS AND BODY 25 REPAIR Refit 12.Position panel assembly, fit bolts and nut and tighten to10 Nm (7lbf.ft). 13.Connect multiplug to motor. 14.Secure harness clips and sleeve. 15.Connect interior handle link to latch and secure with clip. 16.Connect multiplug to solenoid, locate solenoid to mounting panel and tighten screws. 17.Fit and secure link. 18.Remove wedges, lower glass and locate to regulator. Fit bolts and tighten to6 Nm (4 lbf.ft). 19.Raise and lower glass to check operation. 20.Fit plastic sheet.See this Section. 21.Adjust door lock solenoid.See ELECTRICAL, Adjustment.PANEL - MOUNTING - REAR DOOR - FROM 02MY Service repair no - 76.11.29 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.
76CHASSIS AND BODY 26 REPAIR 4.Release clip, detach and remove lock solenoid link. 5.Release clip and disconnect interior handle link from latch mechanism. 6.Remove clip and disconnect sill button link. 7.Release clips securing harness to panel. 8.Disconnect multiplug from solenoid. 9.Release harness sleeve and withdraw harness from door. 10.Remove 5 bolts and 1 nut securing panel. 11.Remove panel assembly. Refit 12.Position door mounting panel assembly, fit bolts and nut and tighten to10 Nm (7lbf.ft). 13.Connect multiplug to solenoid. 14.Secure harness clips and sleeve. 15.Connect interior handle link to latch and secure with clip. 16.Connect link to sill button and fit clip. 17.Fit and secure solenoid link. 18.Remove wedges, lower glass and locate to regulator. Fit bolts and tighten to6 Nm (4 lbf.ft). 19.Raise and lower glass to check operation. 20.Fit plastic sheet.See this Section.
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.
76CHASSIS AND BODY 28 REPAIR 11.Remove 5 screws securing crash pad and remove pad. 12.Remove 5 screws and release fascia console. 13.Disconnect Lucar connection and multiplug from cigar lighter. 14.Disconnect multiplugs from remaining switches and remove console. 15.Remove operating knob from light switch. 16.Remove nut securing light switch and remove switch from console. 17.Release cigar lighter body and remove from console. 18.Remove switches from console. 19.Release tabs and remove radio mounting bracket. Refit 20.Fit radio bracket and secure with tabs. 21.Fit and secure cigar lighter body to console. 22.Fit light switch and secure with nut. 23.Fit operating knob to switch. 24.Fit remaining switches to console.
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.
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.
CHASSIS AND BODY 31 REPAIR 7.Remove seal from glass. CAUTION: Lay glass on felt covered supports and be careful not to damage the obscuration band. Do not stand on edge as this can cause chips which subsequently develop into cracks. Refit 8.Clean glass and fit seal. Ensure seal is fully located on glass. 9.Thoroughly clean the tail door glass mounting flange. 10.Fit drawstring to seal. 11.Lubricate seal. 12.With assistance, position glass and seal to aperture, locate lower edge and fit seal using drawstring. 13.Clean glass and check seal fit. 14.Connect Lucars to heated rear screen. 15.Fit CHMSL assembly.See ELECTRICAL, Repair. 16.Fit wiper arm to spindle, align blade to glass and tighten nut to18 Nm (13 lbf.ft). 17.Fit spare wheel and tighten nuts to45 Nm (33 lbf.ft).TRIM CASING - FRONT DOOR - FROM 02MY Service repair no - 76.34.01 Remove 1.Remove 2 screws securing door pull and remove door pull. 2.Remove screw securing door release escutcheon and remove escutcheon.