1999 LAND ROVER DEFENDER headlamp

77PANEL REPAIRS
2
PANELS
4.Headlamp mounting panel - inner
5.Headlamp mounting panel - outer
6.Wing upper
7.Headlamp reinforcement panel
8.Wing lower
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PANEL REPAIRS
1
REPAIR WING LOWER FRONT
Remove
1.Disconnect both battery leads, negative lead
first. system.
2.Remove wheel arch eyebrow.
3.Remove wheel arch liner.
4. RH side:Remove aerial.
5.Remove air intake hose.
6.Remove bolts securing lower wing.
Refit
7.Prepare and clean panel joint faces.
8.Reverse removal procedure.HEADLAMP MOUNTING PANEL
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect all ECUs.
3.Remove radiator.See COOLING SYSTEM,
Repair.
4.Recover refrigerant from A/C system.See AIR
CONDITIONING, Repair.
5.Remove headlamp.See ELECTRICAL,
Repair.
6. LH side:Remove screen washer bottle.See
WIPERS AND WASHERS, Repair.
7. RH side:Position PAS reservoir aside.
8.Remove bolts and release welds securing panel,
remove panel.
Refit
9.Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding as
shown.
10.Reverse removal procedure.
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77PANEL REPAIRS
2
REPAIR WING UPPER - LH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove headlamp.See ELECTRICAL,
Repair.
3.Remove headlamp mounting panel.See this
Section.
4.Remove radiator.See COOLING SYSTEM,
Repair.
5.Recover refrigerant from A/C system.See AIR
CONDITIONING, Repair.
6.Remove receiver drier.See AIR
CONDITIONING, Repair.
7.Remove relevant A/C pipes.
8.Remove relevant heater intake pipes.
9.Remove screen washer bottle.
10.Remove wheel arch liner.See CHASSIS AND
BODY, Repair.
11.Remove bolts and release welds securing panel,
remove panel.
Refit
12.Prepare and clean panel joint faces.
13.Reverse removal procedure.
14.Align headlamps.See ELECTRICAL,
Adjustment.WING UPPER - RH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove headlamp.See ELECTRICAL,
Repair.
3.Remove headlamp mounting panel.See this
Section.
4.Remove radiator.See COOLING SYSTEM,
Repair.
5.Recover refrigerant from A/C system.See AIR
CONDITIONING, Repair.
6.Remove relevant A/C pipes.
7.Position PAS reservoir aside.
8.Remove wheel arch liner.See CHASSIS AND
BODY, Repair.
9.Remove aerial.
10.Remove vacuum solenoid valve.
11.Release clips securing coolant reservoir.
12.Remove bolts and release welds securing panel,
remove panel.
Refit13.Prepare and clean panel joint faces.
NOTE: LH panel shown
14.Reverse removal procedure.
15.Align headlamps.See ELECTRICAL,
Adjustment.
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PANEL REPAIRS
3
REPAIR WHEEL ARCH - FRONT
Remove
The procedure to change the Inner Front Wheelarch is
the same as for the Wing Upper, except for removal of
the ABS sensors and shield, if fitted.
BULKHEAD ASSEMBLY
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove front lower wing.See this Section.
3.Remove RH and LH front upper wing.See this
Section.
4.Remove headlamp mounting panels.See this
Section.
5.Remove screen aperture.See this Section.
6.Remove both front doors.
7.Remove lower fascia panel.See CHASSIS
AND BODY, Repair.
8. Models with A/C:Remove relevant A/C pipes.
9.Remove front grille.
10.Drain cooling system.See COOLING
SYSTEM, Adjustment.
11.Remove radiator and intercooler.
12. Models with A/C:Remove condensor.
13.Remove air cleaner assembly.
14.Remove heater unit.See HEATING AND
VENTILATION, Repair.
15.Remove brake servo assembly.
16.Remove heater ducts.
17.Remove both front seats.
18.Remove front carpets.
19.Release all relevant harnesses and position
aside.
20.Remove facia support bracket.
Refit
21.Prepare and clean panel joint faces. Ensure all
necessary grommets and sealant is applied to
new bulkhead.
22.Reverse removal procedure.
23.Bleed brake system.See BRAKES,
Adjustment.
24.Align headlamps.See ELECTRICAL,
Adjustment.
25.Water test after refitting.
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PANEL REPAIRS
11
REPAIR TIME SCHEDULES
The following information shows the total time taken to
replace single panels and complete assemblies. This
time includes removal of Mechanical, Electrical and
Trim (MET) items, plus paint times based on Metallic
Clear Over Base Paint.
The times shown were generated by Thatcham (the
Motor Insurance Repair and Research Centre) and
are to be used as a guide only. The operations were
carried out on a 110 Station Wagon.
Panel/assembly replacement times
Panel Description Total time
Bonnet 6.1
Bulkhead 24.2
Door front - each 7.8
Door rear - each 6.9
Door tail 7.7
Headlamp mounting panel LH 8.4
Headlamp mounting panel RH 8.3
Rear lamp mounting panel 9.3
Front screen aperture 7.4
Roof assembly 18.0
Sill and’B’post assembly LH 9.4
Sill and’B’post assembly RH 9.3
Sill panel - front section 4.2
Sill panel - rear section 4.1
Wing front lower 7.0
Wing front upper 8.7
Body side rear assembly - LH 16.7
Body side rear assembly - RH 17.7
Body side lower panel - LH 17.6
Body side lower panel - RH 18.6Combination panel replacement times
The following panel combination times show the total
time to remove/refit body panels, MET items and any
paint processes.
Front end combination panel times
Panel Description Total Time
Grille
Bumper front
Wheelarch eyebrow
Wing - upper
Wing - lower
12.7 LH
12.6 RH
Grille
Bumper front
Wheelarch eyebrow LH & RH
Wing - upper LH & RH
Wing - lower LH & RH
18.2
Grille
Bumper front
Wheelarch eyebrow
Wheelarch front
Wing - upper
Wing - lower
13.1 LH
13.0 RH
Grille
Bumper front
Wheelarch eyebrow LH & RH
Wheelarch front LH & RH
Wing - upper LH & RH
Wing - lower LH & RH
19.0
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WIPERS AND WASHERS
1
REPAIR PUMP - WINDSCREEN WASHER
Service repair no - 84.10.21
Remove
1.Remove headlamp.See ELECTRICAL,
Repair.
2.Position drain tin to collect any fluid spillage.
3.Disconnect multiplug from washer pump.
4.Disconnect hose from washer pump.
5.Release washer pump from reservoir and
discard sealing washer.
Refit
6.Fit new sealing washer and secure pump to
reservoir.
7.Connect hose and multiplug to washer pump.
8.Fit headlamp.See ELECTRICAL, Repair.
9.Fill reservoir with screen cleaning fluid.JET - REAR SCREEN WASHER
Service repair no - 84.30.09
Remove
1.Release and remove both rear side window
finishers.
2.Remove 8 screws securing both rear grab
handles.
3.Remove both rear grab handles.
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86 - ELECTRICAL
CONTENTS
Page
DESCRIPTION AND OPERATION
SECURITY AND CENTRAL DOOR LOCKING 1....................................................
SECURITY AND CENTRAL DOOR LOCKING 2....................................................
ANTI-THEFT ALARM - FROM 02MY 3...................................................................
IMMOBILISATION SYSTEM - FROM 02MY 12......................................................
CENTRAL DOOR LOCKING (CDL) - FROM 02MY 15...........................................
ANTI-THEFT ALARM SYSTEM SELF TEST 17.....................................................
FASCIA CONSOLE 18............................................................................................
HEATED FRONT SCREEN - FROM 02MY 20.......................................................
HEATED FRONT SEATS - FROM 02MY 22..........................................................
ELECTRIC FRONT WINDOWS - FROM 02MY 24.................................................
PASSENGER COMPARTMENT FUSE BOX 26.....................................................
UNDER SEAT FUSE BOX 27.................................................................................
ADJUSTMENT
HEADLAMPS - ALIGN BEAM 1..............................................................................
SOLENOID/MOTOR - FRONT DOOR - ADJUST 1................................................
REPAIR
BELT - AUXILLARY DRIVE 1.................................................................................
HARNESS - INJECTORS 1....................................................................................
STARTER MOTOR 2..............................................................................................
CENTRE HIGH MOUNTED STOP LIGHT (CHMSL) - UP TO 02MY 2...................
ALTERNATOR 3.....................................................................................................
HORN - LH 4...........................................................................................................
HEADLAMP 5.........................................................................................................
LAMP - TAIL 6.........................................................................................................
RADIO6 ..................................................................................................................
SPEAKER - FRONT 7.............................................................................................
SWITCH - TRANSMISSION BRAKE 7...................................................................
LAMP - FRONT FLASHER 8..................................................................................
BATTERY - DISCONNECT - FROM 02MY 8..........................................................
MOTOR & REGULATOR - FRONT DOOR - FROM 02MY 9..................................
SWITCH - FASCIA - FROM 02MY 10.....................................................................
HARNESS - FRONT DOOR - FROM 02MY 10.......................................................
SOLENOID/MOTOR - TAIL DOOR - FROM 02MY 11............................................
SOLENOID/MOTOR - FRONT DOOR - FROM 02MY 12.......................................
SOLENOID/MOTOR - REAR DOOR - FROM 02MY 13.........................................
HARNESS - REAR DOOR - FROM 02MY 14.........................................................
REVERSE AND FOG GUARD LAMP - BULB 15....................................................
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86 - ELECTRICAL
CONTENTS
Page
LAMP ASSEMBLY - CENTRE HIGH MOUNTED STOP LIGHT (CHMSL) -
FROM 02MY 16......................................................................................................
FLASHER UNIT - HAZARD WARNING - FROM 02MY 16.....................................
RELAY - HEATED FRONT SCREEN - FROM 02MY 17........................................
RELAY - REAR FOG GUARD - FROM 02MY 18...................................................
RELAY - STARTER - FROM 02MY 19...................................................................
SWITCH - HEADLAMP LEVELLING - FROM 02MY 19.........................................
CIGAR LIGHTER - FRONT - FROM 02MY 20........................................................
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