Land Rover Defender 1999 2002my Workshop Supplement Body Repair 3rd Edition Rover Manual

76CHASSIS AND BODY
32
REPAIR
3.Remove sill button guide.
4.Remove 2 studs securing trim casing.
5.Using a trim removal tool, release 11 fasteners
and remove trim casing.
NOTE: Do not carry out further
dismantling if component is removed for
access only.
6.Remove fasteners and anti-vibration pad from
trim casing
Refit
7.Fit anti-vibration pad and fasteners to trim
casing.
8.Position trim casing, align fasteners with holes in
door and press firmly into position.
9.Fit trim studs to casing.
10.Fit sill...

CHASSIS AND BODY
33
REPAIR TRIM CASING - TAIL DOOR - FROM 02MY
Service repair no - 76.34.09
Remove
1.Remove 2 bolts securing rear door grab handle,
remove handle.
2.Remove escutcheon.
3.Carefully release 9 fasteners securing trim
casing to rear door and remove casing.
NOTE: Do not carry out further
dismantling if component is removed for
access only.4.Remove 9 fasteners from trim pad.
Refit
5.Fit fasteners to trim casing.
6.Position trim casing and secure fasteners.
7.Fit escutcheon.
8.Fit grab handle...

76CHASSIS AND BODY
34
REPAIR PLASTIC SHEET - FRONT DOOR - FROM 02MY
Service repair no - 76.34.26
Remove
1.Remove front door trim casing.See this
Section.
2.Release and discard plastic sheet.
Refit
3.Clean door contact area with white spirit.
4.Apply adhesive sealing strip to plastic sheet.
5.Position new plastic sheet to door and seal in
position, by applying hand pressure to centre
bottom of sheet first then move out from this
point in both directions applying an even
pressure to the seal, smooth out...

CHASSIS AND BODY
35
REPAIR LOCK - TAIL DOOR - FROM 02MY
Service repair no - 76.37.16
Remove
1.Remove tail door trim casing.See this Section.
2.Remove 4 nuts securing tail door lock.
3.Partially withdraw lock assembly, carefully
disconnect central door locking rod from fulcrum
arm.
4.Remove lock assembly.
5.Remove door lock gasket.
NOTE: Do not carry out further
dismantling if component is removed for
access only.
6.Insert key in lock, depress lock barrel plunger
and withdraw barrel from lock.Refit
7.Fit...

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,...

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...

76CHASSIS AND BODY
38
REPAIR 

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...

77 - PANEL REPAIRS
CONTENTS
Page
BODY SIDE REAR - UPPER 6...............................................................................
BODY SIDE REAR - LOWER - ASSEMBLY 7........................................................
BODY SIDE REAR - PANEL 8................................................................................
REAR LAMP PANEL 9............................................................................................
REAR CROSSMEMBER PANEL...

PANEL REPAIRS
1
INFORMATION BODY REPAIRS
Body shells are of riveted, bolted and welded
construction and are bolted to the chassis frame.
It is essential that design dimensions and strength are
restored in accident rectification. It is important that
neither structural weakness nor excessive local
stiffness are introduced into the vehicle during body or
chassis repair.
Repairs usually involve a combination of operations
ranging from straightening procedures to renewal of
either individual panels or panel...