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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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86ELECTRICAL 2 REPAIR STARTER MOTOR Service repair no - 86.60.01 Remove 1.Remove battery cover. 2.Disconnect battery negative lead. 3.Remove fixings and remove underbelly panel. 4.Disconnect Lucar from starter solenoid. 5.Remove nut and disconnect battery lead from starter solenoid. 6.Remove nut and 2 bolts securing starter to gearbox housing. Remove starter. Refit 7.Clean starter motor and mating face. 8.Position starter and tighten nut and 2 bolts to27 Nm (20 lbf.ft) 9.Connect lead to starter solenoid and tighten nut. 10.Connect Lucar to starter solenoid. 11.Fit underbelly panel. 12.Reconnect battery negative lead. 13.Fit battery cover.CENTRE HIGH MOUNTED STOP LIGHT (CHMSL) - UP TO 02MY Service repair no - 86.41.32 Remove 1.Remove 2 screws securing lamp cover. 2.Remove lamp cover. 3.Disconnect 2 Lucars from bulb holder. 4.Remove 2 nuts securing lamp to tail door. 5.Remove lamp. 6.Collect gasket. Refit 7.Position gasket. 8.Position lamp. 9.Secure lamp with nuts. 10.Connect Lucars to bulb holder. 11.Fit lamp cover. 12.Secure cover with screws.
ELECTRICAL 3 REPAIR ALTERNATOR Service repair no - 86.10.02 Remove 1.Remove auxilliary drive belt.See this Section. 2.Release cover and remove nut securing lead to alternator. 3.Disconnect alternator multiplug. 4.Remove bolt (LH thread) and remove auxiliary drive belt tensioner. 5.Remove bolt securing support stay to alternator. 6.Release clip securing lubrication drain hose to vacuum pump. 7.Loosen vacuum pump lubrication pipe from cylinder head and discard’O’ring. 8.Remove bolt securing alternator and release from mounting bracket. 9.Disconnect hose from vacuum pump. 10.Remove alternator taking care not to damage radiator cooling fins. 11.Remove 4 bolts, and remove vacuum pump from alternator. CAUTION: Plug the connections.
86ELECTRICAL 4 REPAIR Refit 12.Clean mating face of alternator and vacuum pump. 13.Fit vacuum pump to alternator and tighten bolts to10 Nm (7 lbf.ft). 14.Position alternator and connect multiplug. 15.Connect vacuum hose and oil drain hose to vacuum pump and secure clip. 16.With assistance align alternator to mounting bracket and fit but do not tighten bolt. 17.Fit bolt securing support stay to alternator and tighten to25 Nm (18 lbf.ft). 18.Tighten alternator to mounting bracket bolt to45 Nm (33 lbf.ft). 19.Using new’O’ring, fit and tighten lubrication pipe union to10 Nm (8 lbf.ft). 20.Connect lead to alternator and tighten nut to6 Nm (4.4 lbf.ft). 21.Fit auxilliary drive belt tensioner and tighten bolt to50 Nm (37 lbf.ft). 22.Fit auxilliary drive belt.See this Section.HORN - LH Service repair no - 86.30.10 Remove 1.Remove LH headlamp.See this Section. 2.Disconnect horn multiplug. 3.Remove nut and remove horn from mounting bracket. Refit 4.Position horn, tighten securing and connect multiplug. 5.Fit LH headlamp.See this Section.
ELECTRICAL 5 REPAIR HEADLAMP Service repair no - 86.40.49 Remove 1.Remove 4 screws and release side and indicator lamps from wing. 2.Disconnect multiplugs and remove side and indicator lamps. 3.Remove 2 screws and remove headlamp finisher. 4.Remove 4 screws securing headlamp to wing, disconnect multiplugs and remove headlamp. 5.Remove headlamp seal.Refit 6.Fit headlamp seal. 7.Position headlamp, connect multiplugs, fit and tighten headlamp screws. 8.Fit headlamp finisher and secure with screws. 9.Position side and indicator lamps, connect multiplugs and secure with screws. 10.Reset headlamp alignment.See Adjustment.
86ELECTRICAL 6 REPAIR LAMP - TAIL Service repair no - 86.40.70 Remove 1.Remove 2 screws securing tail lamp to body. 2.Disconnect multiplug and remove lamp. Refit 3.Position tail lamp and connect multiplug. 4.Fit and tighten lamp securing screws.RADIO Service repair no - 86.50.03 Remove1.Using toolSMD 4091release radio from cage. 2.Disconnect coaxial cable from radio. 3.Disconnect 2 multiplugs from radio. 4.Remove radio from fascia. Refit 5.Position radio to fascia and connect multiplugs. 6.Connect coaxial cable to radio. 7.Secure radio in cage.
ELECTRICAL 7 REPAIR SPEAKER - FRONT Service repair no - 86.50.15 Remove 1.Remove 4 screws securing speaker to fascia. 2.Release speaker from fascia and disconnect 2 Lucars. 3.Remove speaker. Refit 4.Position speaker to fascia and connect Lucars. 5.Fit speaker to fascia and secure with screws.SWITCH - TRANSMISSION BRAKE Service repair no - 86.65.45 Remove1.Release cover from transmission brake lever. 2.Remove 2 bolts and release transmission brake lever from body. 3.Disconnect Lucar from transmission brake warning switch. 4.Remove 2 screws securing switch from brake lever and remove switch. Refit 5.Fit switch to brake lever and tighten screws. 6.Connect switch Lucar. 7.Position brake lever and tighten bolts to22 Nm (16 lbf.ft). 8.Position cover to brake lever.
86ELECTRICAL 8 REPAIR LAMP - FRONT FLASHER Service repair no - 86.40.42 Remove 1.Remove 2 screws securing flasher lamp to front wing. 2.Disconnect multiplug and remove lamp. Refit 3.Position flasher lamp and connect multiplug. 4.Fit and tighten lamp securing screws.BATTERY - DISCONNECT - FROM 02MY Service repair no - 86.15.99 Remove 1.Remove front seat cushion. 2.Release clip and remove battery cover. 3.Loosen bolt securing negative earth lead, do not remove lead at this stage. 4.Fit ignition key, turn to position’II’. Turn ignition off, remove key from lock and immediately remove negative lead. Refit 5.Connect negative lead to negative terminal and tighten bolt to10 Nm (7 lbf.ft). 6.Fit and secure battery cover. 7.Fit seat cushion.
ELECTRICAL 9 REPAIR MOTOR & REGULATOR - FRONT DOOR - FROM 02MY Service repair no - 86.25.03 Remove 1.Remove plastic sheet.See CHASSIS AND BODY, Repair. 2.Lower glass and remove 2 bolts securing door glass to regulator. 3.Release glass from regulator, raise and wedge in raised position. 4.Disconnect multiplug from motor. 5.Remove 4 bolts and 2 nuts securing motor and regulator assembly. 6.Release and remove motor and regulator assembly. Refit 7.Fit motor and regulator assembly, fit nuts and bolts and tighten to10 Nm (7 lbf.ft). 8.Connect multiplug to motor. 9.Remove wedges, lower glass and locate to regulator. Fit bolts and tighten to6 Nm (4 lbf.ft). 10.Raise and lower glass to check operation. 11.Fit plastic sheet.See CHASSIS AND BODY, Repair.
86ELECTRICAL 10 REPAIR SWITCH - FASCIA - FROM 02MY Service repair no - 86.25.18 Remove 1.Remove radio.See this Section. 2.Release switch, disconnect multiplug and remove switch. Refit 3.Connect multiplug to switch and fit switch to panel. 4.Fit radio.See this Section.HARNESS - FRONT DOOR - FROM 02MY Service repair no - 86.25.20 Remove 1.Remove door lock solenoid.See this Section. 2.Carefully peel back section of plastic sheet for access to harness. 3.Release clips securing harness to panel. 4.Disconnect multiplug from motor. 5.Release harness sleeve and withdraw harness from door. 6.Release harness sleeve and withdraw harness multiplugs from’A’post. 7.Disconnect 2 multiplugs and remove harness.
ELECTRICAL 11 REPAIR Refit 8.Position harness and connect multiplugs. 9.Feed multiplugs into’A’post and secure harness sleeve. 10.Connect multiplug to motor. 11.Secure harness clips and sleeve. 12.Secure plastic sheet. 13.Fit door lock solenoid.See this Section.SOLENOID/MOTOR - TAIL DOOR - FROM 02MY Service repair no - 86.26.02 Remove 1.Remove tail door trim casing.See CHASSIS AND BODY, Repair. 2.Disconnect multiplug from solenoid. 3.Remove bolt and screw securing solenoid to door. 4.Release clip securing harness to solenoid mounting bracket. 5.Remove solenoid assembly from operating rod. 6.Remove 2 screws securing solenoid to mounting bracket.