1999 LAND ROVER DEFENDER service

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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CHASSIS AND BODY
25
REPAIR Refit
12.Position panel assembly, fit bolts and nut and
tighten to10 Nm (7lbf.ft).
13.Connect multiplug to motor.
14.Secure harness clips and sleeve.
15.Connect interior handle link to latch and secure
with clip.
16.Connect multiplug to solenoid, locate solenoid to
mounting panel and tighten screws.
17.Fit and secure link.
18.Remove wedges, lower glass and locate to
regulator. Fit bolts and tighten to6 Nm (4 lbf.ft).
19.Raise and lower glass to check operation.
20.Fit plastic sheet.See this Section.
21.Adjust door lock solenoid.See ELECTRICAL,
Adjustment.PANEL - MOUNTING - REAR DOOR - FROM 02MY
Service repair no - 76.11.29
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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CHASSIS AND BODY
27
REPAIR FACIA CONSOLE - FROM 02MY
Service repair no - 76.25.03
Remove
1.Disconnect battery earth lead.See
ELECTRICAL, Repair.
2.Remove radio.See ELECTRICAL, Repair.
3.Remove 4 screws securing instrument pack and
release pack from fascia.
4.Disconnect 2 multiplugs from warning lamp
panel.
5.Disconnect instrument pack multiplug from main
harness.
6.Remove instrument pack.
7.Remove 3 screws securing heater control and
release control from fascia.
8.Carefully prise Land Rover decal from grab
handle.
9.Remove 2 screws securing grab handle and
remove handle.
10.Remove 4 screws and remove demister vents.
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CHASSIS AND BODY
29
REPAIR 25.Position console and connect Lucar and
multiplug to cigar lighter.
26.Connect multiplugs to remaining switches.
27.Fit console and secure with screws.
28.Fit crash pad and secure with screws.
29.Fit demister vents and secure with screws.
30.Fit grab handle, secure with screws and fit Land
Rover decal.
31.Fit heater control to fascia and secure with
screws.
32.Position instrument pack and connect multiplugs.
33.Fit instrument pack to fascia and secure with
screws.
34.Fit radio.See ELECTRICAL, Repair.
35.Connect battery earth lead.See ELECTRICAL,
Repair.GLASS - REAR DOOR - FROM 02MY
Service repair no - 76.31.02
Remove
1.Remove rear door mounting panel.See this
Section.
2.Loosen 2 nuts and remove door check strap
torsion bar and plate.
3.Remove check strap.
4.Remove inner and outer waist seal.
5.Remove screw from each glass channel.
6.Lower glass to bottom of door, lift over lower
edge and withdraw from door.
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76CHASSIS AND BODY
30
REPAIR Refit
7.Insert glass into channels and carefully push to
top of frame.
8.Secure glass channels with screws. Ensure
screw heads are down below bottom of channels
to prevent damage to glass.
9.Fit inner and outer waist seal to door.
10.Fit check strap.
11.Fit check strap torsion bar and tighten nuts to10
Nm (7 lbf.ft).
12.Fit rear door mounting panel.See this Section.GLASS/SEALING RUBBER - TAIL DOOR - FROM
02MY
Service repair no - 76.31.22
Remove
1.Remove spare wheel from tail door.
2.Raise nut cover, remove nut and release wiper
arm.
3.Open rear door.
4.Remove CHMSL assembly.See
ELECTRICAL, Repair.
5.Disconnect 4 Lucar connections.
6.With assistance, from inside of vehicle apply
pressure to glass, relieve seal lip and carefully
remove glass.
WARNING: Wear suitable eye protection
when removing and refitting glass.
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CHASSIS AND BODY
31
REPAIR 7.Remove seal from glass.
CAUTION: Lay glass on felt covered
supports and be careful not to damage the
obscuration band. Do not stand on edge
as this can cause chips which subsequently
develop into cracks.
Refit
8.Clean glass and fit seal. Ensure seal is fully
located on glass.
9.Thoroughly clean the tail door glass mounting
flange.
10.Fit drawstring to seal.
11.Lubricate seal.
12.With assistance, position glass and seal to
aperture, locate lower edge and fit seal using
drawstring.
13.Clean glass and check seal fit.
14.Connect Lucars to heated rear screen.
15.Fit CHMSL assembly.See ELECTRICAL,
Repair.
16.Fit wiper arm to spindle, align blade to glass and
tighten nut to18 Nm (13 lbf.ft).
17.Fit spare wheel and tighten nuts to45 Nm (33
lbf.ft).TRIM CASING - FRONT DOOR - FROM 02MY
Service repair no - 76.34.01
Remove
1.Remove 2 screws securing door pull and
remove door pull.
2.Remove screw securing door release
escutcheon and remove escutcheon.
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