1999 LAND ROVER DEFENDER Workshop Manual

76CHASSIS AND BODY
20
REPAIR
14.Carefully prise Land Rover decal from grab
handle.
15.Remove 2 screws securing grab handle to crash
pad and lower fascia panel.
16.Remove grab handle.
17.Remove 4 screws securing demister vents to
crash pad.
18.Remove both demister vents.
19.Remove 3 screws securing crash pad to
bulkhead.
20.Remove crash pad.
21.Release radio from fascia.
22.Disconnect 2 multiplugs and aerial from radio.23.Remove radio.
24.Remove 2 trim studs securing radio housing to
fascia.
25.Remove radio housing.
26.Remove auxilliary switch panel.See this
Section.
27.Remove auxilliary switch panel cover.
28.Remove interior fuse box cover.
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CHASSIS AND BODY
21
REPAIR
29.Remove 2 screws securing each footwell vent
and remove vents from lower fascia.
30.Remove screw securing each door check strap
cover and remove both covers.
31.Remove 3 screws securing wiper motor cover to
bulkhead.
32.Remove wiper motor cover.
33.Remove 3 screws securing finisher rail to lower
fascia.
34.Remove finisher rail.
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76CHASSIS AND BODY
22
REPAIR
35.Remove 7 trim clips securing trim upper fascia
trim casing to bulkhead.
36.Carefully fold back trim casing over fresh air vent
operating levers and remove.
37.Release demist hose from parcel shelf.
38.Remove 18 screws securing parcel shelf to
lower fascia panel.
39.Remove parcel shelf.
40.Remove 7 screws securing bottom edge of lower
fascia panel to bulkhead.
41.Remove both retaining plates and lower footwell
covers.
42.Remove 2 bolts securing top of lower fascia to
bulkhead.
43.With assistance, remove lower fascia.Refit
44.With assistance, fit lower fascia.
45.Fit 2 bolts securing top of lower fascia to
bulkhead.
46.Fit both retaining plates and footwell covers to
lower fascia.
47.Fit 7 screws securing bottom edge of lower
fascia to bulkhead.
48.Fit parcel shelf to lower fascia and secure with
screws.
49.Fit demist hose to parcel shelf.
50.Carefully manoeuvre upper fascia trim casing
over fresh air vents and fit to fascia.
51.Fit trim clips securing trim casing to bulkhead.
52.Fit finisher rail to lower fascia and secure with
screws.
53.Fit wiper motor cover and secure with screws.
54.Fit both door check strap covers and secure with
screws.
55.Fit both footwell vents to lower fascia and secure
with screws.
56.Fit interior fuse box cover.
57.Fit auxilliary switch panel cover.
58.Fit auxilliary switch panel.See this Section.
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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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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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76CHASSIS AND BODY
26
REPAIR
4.Release clip, detach and remove lock solenoid
link.
5.Release clip and disconnect interior handle link
from latch mechanism.
6.Remove clip and disconnect sill button link.
7.Release clips securing harness to panel.
8.Disconnect multiplug from solenoid.
9.Release harness sleeve and withdraw harness
from door.
10.Remove 5 bolts and 1 nut securing panel.
11.Remove panel assembly.
Refit
12.Position door mounting panel assembly, fit bolts
and nut and tighten to10 Nm (7lbf.ft).
13.Connect multiplug to solenoid.
14.Secure harness clips and sleeve.
15.Connect interior handle link to latch and secure
with clip.
16.Connect link to sill button and fit clip.
17.Fit and secure solenoid 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.
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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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