1999 LAND ROVER DEFENDER service

76CHASSIS AND BODY
10
REPAIR DOOR - TAIL - REMOVE
Service repair no - 76.28.19.99
Remove
1.Remove 3 nuts and remove spare wheel.
2.Remove bolt securing check strap to body.
3.Release harness grommet from harness cover,
disconnect connectors and multiplug.
4.Release harness cover and harness from body.
5.With assistance, remove 6 screws securing door
hinges to body and remove door.
Refit
6.With assistance, position door and fit but do not
tighten bolts.
7.Position check strap and tighten bolt.
8.Align door to body and tighten bolts.
9.Position harness through body and secure
harness cover.
10.Secure harness connectors and multiplug.
11.Secure harness grommet to body.
12.Position spare wheel to tail door and tighten
nuts.
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CHASSIS AND BODY
11
REPAIR GLASS/SEALING RUBBER - TAIL DOOR - UP TO
02MY
Service repair no - 76.31.22
Remove
1.Remove high level stop lamp.See
ELECTRICAL, Repair.
2.Remove 3 nuts and remove spare wheel.
3.Raise cover, remove nut and remove rear wiper
arm assembly.
4.Disconnect 2 HRW Lucars.
5.Remove 30 screws securing door glass
retainers.
6.Remove door glass retainers.
7.Remove door glass sealing strips.
8.Release and remove door glass.Refit
9.Clean old sealant from glass aperture.
10.Apply sealant to glass aperture.
11.Position door glass, fit sealing strips and glass
retainers and secure with screws.
12.Connect HRW lucars.
13.Fit high level stop lamp.See ELECTRICAL,
Repair.
14.Fit rear wiper arm assembly and secure with nut.
15.Position spare wheel and secure with nuts.
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76CHASSIS AND BODY
12
REPAIR SEAT BELT - FRONT
Service repair no - 76.73.13
Remove
1.Remove cap from seat belt guide bolt.
2.Remove bolt securing seat belt guide to’B’post.
3.Release belt from’B’post mounting.
4.Remove 3 bolts securing belt bracket to seat
base.
5.Remove 2 studs securing seat belt retaining clip.
6.Remove retaining clip.
7.Remove bolt securing inertia reel to body.
8.Remove automatic belt assembly.
9.Remove 2 bolts securing stalk to body.
10.Remove stalk.
Refit
11.Position stalk and tighten bolts.
12.Position automatic belt assembly to body and
tighten bolt to38 Nm
13.Unreel portion of belt.
14.Position bracket to seat base, tighten bolts.
15.Position belt to’B’post mounting and tighten bolt
to32 Nm (24 lbf.ft).
16.Fit cap to bolt head.
17.Position belt retaining clip to seat base and
secure with studs.
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CHASSIS AND BODY
13
REPAIR SEAT BELT - CENTRE - REAR
Service repair no - 76.73.20
Remove
1.Remove seat belt bolt caps and remove bolts.
2.Remove seat belt and stalk.
Refit
3.Position seat belt and stalk.
4.Fit and tighten bolts to32 Nm (24 lbf.ft),and fit
bolt caps.SEAT BELT - REAR - SIDE
Service repair no - 76.73.23
Remove
1.Remove cap from seat belt guide bolt.
2.Remove seat belt upper and lower securing
bolts.
3.Remove seat belt guide from’D’post finisher.
4.Remove 2 studs securing finisher to’D’post.
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76CHASSIS AND BODY
14
REPAIR
5.Release finisher from body upper rail and’D’
post.
6.Pull seat belt through’D’post finisher.
7.Remove bolt securing seat belt to’D’post and
remove belt assembly.
Refit
8.Position seat belt assembly to’D’post and
tighten bolt to32 Nm (24 lbf.ft).
9.Extend seat belt and position through’D’post
finisher.
10.Fit and tighten seat belt upper and lower
securing bolts to32 Nm (24 lbf.ft).
11.Secure’D’post finisher to body upper rail.
12.Fit belt guide to’D’post finisher and fit finisher
retaining studs.
13.Fit cap to seat belt bolt.SEAT - REAR
Service repair no - 78.10.48.99
Remove
1.Remove bolts securing rear seat to hinges and
collect spacer.
2.Remove rear seat.
Refit
3.Position rear seat and align to hinges.
4.Fit spacer and tighten bolts.
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CHASSIS AND BODY
15
REPAIR COVER - CUSHION - REAR SEAT
Service repair no - 78.40.04
Remove
1.Remove rear seat.See this Section.
2.Remove 2 bolts securing squab to cushion
frame.
3.Remove squab and collect spacer.
4.Remove 17 screws securing base board to seat
cushion frame and remove board.
5.Remove 2 trim retaining clips.
6.Release cover retainers from seat frame.
7.Remove cover from cushion pad.
Refit
8.Position cover to cushion pad and secure
retainers to seat frame.
9.Fit trim retaining clips.
10.Position base board and tighten screws.
11.Position and align squab to cushion frame.
12.Fit spacer and tighten securing bolts.
13.Fit rear seat.See this Section.
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76CHASSIS AND BODY
16
REPAIR COVER - SQUAB - REAR SEAT
Service repair no - 78.90.13
Remove
1.Remove rear seat.See this Section.
2.Remove 2 screws and remove squab striker.
3.Remove 2 bolts securing squab to cushion
frame.
4.Remove squab stop bolt.
5.Remove squab and collect spacer.
6.Release velcro securing squab cover edges and
fold cover over squab pad.
7.Remove squab cover.
Refit
8.Position cover to squab pad, align to its fitted
position and secure velcro.
9.Position and align squab to cushion frame.
10.Fit spacer and tighten securing bolts.
11.Fit and tighten squab stop bolt.
12.Fit squab striker and tighten screws.
13.Fit rear seat.See this Section.REGULATOR - REAR DOOR GLASS
Service repair no - 76.31.46
Remove
1.Remove rear door trim casing.See this
Section.
2.Carefully release plastic sheet from rear door.
3.Remove 2 bolts securing door glass to regulator.
4.Raise glass and secure with a suitable wedge.
5.Remove 4 bolts securing glass regulator
assembly to door.
6.Manoeuvre regulator through access hole at
bottom of the door.
Refit
7.Clean mating face of regulator and door glass.
8.Lubricate regulator with grease.
9.Position regulator in door and secure with bolts.
10.Remove wedge holding glass and align glass to
regulator.
11.Secure glass to regulator and fit and tighten
bolts.
12.Fit plastic sheet to rear door.
13.Fit rear door trim casing.See this Section.
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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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