1999 LAND ROVER DEFENDER roof

77PANEL REPAIRS
4
REPAIR SCREEN APERTURE
Remove
1.Disconnect both battery leads, negative lead
first.
2.Raise side of vehicle.
3.Remove front and centre headlining sections.
4.Remove both’A’post upper trims.
5.Remove front door aperture seals.
6.Release upper front corner of rear door aperture
seal.
7.Remove both wiper arms.See WIPERS AND
WASHERS, Repair.
8.Remove front screen.
9.Remove all roof fixings, back to the’B/C’post.
10.Release sealant securing front edge of roof.
11.Insert wedges into top of both’B/C’posts. This
will allow access for removal of screen aperture.
12.With assistance remove screen aperture.Refit
13.Prepare and clean panel joint faces.
14.Reverse removal procedure. Fit new foam seal
to top edge of aperture.
NOTE: When refitting, ensure screen
aperture is correctly fitted onto location
pins in bulkhead.
15.When applying sealant to top edge of aperture,
the correct colour sealant must be used, see
note below.
NOTE: White roof vehicles use a white
sealant. Coloured roof vehicles use a
black sealant.
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77PANEL REPAIRS
6
REPAIR CORNER CAPPING
The Corner Capping is not replaced as a single panel.
It is replaced in conjunction with either the Body Side
Lower Panel or Body Side Assembly. The procedure
to replace the Corner Capping is shown in the Body
Side Lower Panel procedure.
BODY SIDE CAPPING
The Body Side Capping is not replaced as a single
panel. It is replaced in conjunction with either the
Body Side Lower Panel or Body Side Assembly. The
procedure to replace the Body Side Capping is shown
in the Body Side Lower Panel procedure.
BODY SIDE REAR - UPPER
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove front, centre and rear sections of
headlining.
3.Release upper edge of front door aperture seal.
4.Release upper edge of rear door aperture seal.
5.Remove fixings from front edge of roof, and
along side being replaced.
6.Release sealant securing front edge of roof.
7.Insert wedges into top of both’B/C’posts. This
will allow access for removal of body side.
8. RH side:Remove tail door.See CHASSIS
AND BODY, Repair.
9.Remove side window.
10.Remove rear sixth light.
11.Remove all bolts securing upper body side.
Refit
12.Prepare and clean panel joint faces.
13.Reverse removal procedure.
NOTE: When refitting, ensure body side
upper is correctly fitted onto location pins.
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77PANEL REPAIRS
10
REPAIR ROOF ASSEMBLY
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove rear bench seats.
3.Remove front, centre and rear sections of
headlining.
4.Remove all bolts securing roof.
NOTE: Carefully cut sealant securing front
edge of roof to windscreen aperture.
Refit
5.Prepare and clean panel joint faces.
6.Reverse removal procedure.
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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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ELECTRICAL
7
DESCRIPTION AND OPERATION Alarm Sounders
1.Battery Backed Up Sounder (BBUS)
2.Alarm sounder
Two types of alarm sounder are available, dependant on the vehicle market configuration.
A Battery Backed-Up Sounder (BBUS) is used in some markets and located in the LH front wing, behind the
headlamp. This is a tamper proof sounder with its own power supply which allows it to continue operating even if
disconnected from the vehicle power supply. The BBUS is connected to a permanent battery supply via fuse 7 in
the under seat fuse box. Two further connections are made to the anti-theft alarm ECU and a fourth connection is
to an earth header. If the BBUS is disconnected without first being disarmed by the anti-theft alarm ECU, it will
operate for 4.5 minutes.
To disarm the BBUS, when the battery is to be disconnected for instance, the ignition must be turned on to
position II and back to the off position , after which a 17 second delay is initiated to allow the battery or BBUS
connector to be disconnected. If the BBUS sounds, it can be disarmed by unlocking the vehicle with the remote
handset.
Where a BBUS is not specified, a standard vehicle horn is used for the alarm sounder and is located in the LH
front wing, behind the headlamp. The sounder is operated by an alarm relay which is controlled by the anti-theft
alarm ECU. The relay receives a permanent battery supply via fusible link 6 in the under seat fuse box. The relay
coil is connected to the anti-theft alarm ECU which provides an earth for the coil when horn operation is required.
This operates the relay contacts and supplies battery voltage to the sounder, causing it to operate.
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