1999 LAND ROVER DEFENDER lock

76CHASSIS AND BODY
2
REPAIR TRIM CASING - TAIL DOOR - UP TO 02MY
Service repair no - 76.34.09
Remove
1.Remove 2 bolts securing grab handle to tail
door.
2.Remove grab handle.
3.Remove 2 screws securing wiper motor cover.
4.Remove wiper motor cover.
5.Remove 7 screws securing trim casing to door.
6.Remove 2 screws securing wiper motor harness
cover.
7.Remove harness cover.
8.Release 7 of 8 trim studs securing trim casing.
9.Remove trim casing from remaining stud.
10.Collect door lock cover.Refit
11.Position door lock cover.
12.Position trim casing and secure trim casing.
13.Position harness cover and secure with screws.
14.Secure trim pad with screws.
15.Fit wiper motor cover and secure with screws.
16.Fit grab handle and secure with screws.
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CHASSIS AND BODY
5
REPAIR
13.Remove 4 bolts securing radiator mounting
bracket to wing.
14.Loosen screw and release bonnet lock inner
cable from bonnet lock.
15.Release bonnet lock outer cable from from
bonnet lock.
16.Push centre pins from studs securing wheel arch
extension to wing, remove studs and remove
wheel arch extension.
17.Remove bolt securing inner and outer wing to
chassis.
18.Remove nut and bolt securing support stay to
wing.
19.Remove 4 bolts securing wing to’A’post.
20.Remove bolt securing wing to bulkhead.
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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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CHASSIS AND BODY
17
REPAIR TRIM CASING - REAR DOOR
Service repair no - 76.34.04.99
Remove
1.Remove screw securing door handle
escutcheon.
2.Remove escutcheon.
3.Remove interior lock button bezel.
4.Remove retaining clip and remove door glass
regulator handle.
5.Release covers and remove 2 screws securing
door pull to door.
6.Carefully release 12 clips securing trim casing to
door and remove door casing.Refit
7.Fit trim casing to door and secure with clips.
8.Fit door glass regulator handle.
9.Fit escutcheon to door handle and tighten screw.
10.Fit door lock button bezel.
11.Fit door pull and secure with screws.
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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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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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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.
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