1999 LAND ROVER DEFENDER Workshop Manual

76CHASSIS AND BODY
28
REPAIR
11.Remove 5 screws securing crash pad and
remove pad.
12.Remove 5 screws and release fascia console.
13.Disconnect Lucar connection and multiplug from
cigar lighter.
14.Disconnect multiplugs from remaining switches
and remove console.
15.Remove operating knob from light switch.
16.Remove nut securing light switch and remove
switch from console.
17.Release cigar lighter body and remove from
console.
18.Remove switches from console.
19.Release tabs and remove radio mounting
bracket.
Refit
20.Fit radio bracket and secure with tabs.
21.Fit and secure cigar lighter body to console.
22.Fit light switch and secure with nut.
23.Fit operating knob to switch.
24.Fit remaining switches to console.
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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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76CHASSIS AND BODY
32
REPAIR
3.Remove sill button guide.
4.Remove 2 studs securing trim casing.
5.Using a trim removal tool, release 11 fasteners
and remove trim casing.
NOTE: Do not carry out further
dismantling if component is removed for
access only.
6.Remove fasteners and anti-vibration pad from
trim casing
Refit
7.Fit anti-vibration pad and fasteners to trim
casing.
8.Position trim casing, align fasteners with holes in
door and press firmly into position.
9.Fit trim studs to casing.
10.Fit sill button guide.
11.Fit escutcheon to door handle and secure with
screw.
12.Fit door pull and secure with screws.
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CHASSIS AND BODY
33
REPAIR TRIM CASING - TAIL DOOR - FROM 02MY
Service repair no - 76.34.09
Remove
1.Remove 2 bolts securing rear door grab handle,
remove handle.
2.Remove escutcheon.
3.Carefully release 9 fasteners securing trim
casing to rear door and remove casing.
NOTE: Do not carry out further
dismantling if component is removed for
access only.4.Remove 9 fasteners from trim pad.
Refit
5.Fit fasteners to trim casing.
6.Position trim casing and secure fasteners.
7.Fit escutcheon.
8.Fit grab handle and tighten bolts to10 Nm (7
lbf.ft).
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76CHASSIS AND BODY
34
REPAIR PLASTIC SHEET - FRONT DOOR - FROM 02MY
Service repair no - 76.34.26
Remove
1.Remove front door trim casing.See this
Section.
2.Release and discard plastic sheet.
Refit
3.Clean door contact area with white spirit.
4.Apply adhesive sealing strip to plastic sheet.
5.Position new plastic sheet to door and seal in
position, by applying hand pressure to centre
bottom of sheet first then move out from this
point in both directions applying an even
pressure to the seal, smooth out any creases.
6.Fit front door trim casing.See this Section.PLASTIC SHEET - REAR DOOR - FROM 02MY
Service repair no - 76.34.28
Remove
1.Remove rear door trim casing.See this
Section.
2.Remove nut and disconnect check strap.
3.Release and discard plastic sheet.
Refit
4.Clean door contact area with white spirit.
5.Apply adhesive sealing strip to plastic sheet.
6.Position new plastic sheet to door and seal in
position, by applying hand pressure to centre
bottom of sheet first then move out from this
point in both directions applying an even
pressure to the seal, smooth out any creases.
7.Connect check strap, fit nut and tighten
sufficiently to allow check strap to pivot without
rattling.
8.Fit rear door trim casing.See this Section.
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CHASSIS AND BODY
35
REPAIR LOCK - TAIL DOOR - FROM 02MY
Service repair no - 76.37.16
Remove
1.Remove tail door trim casing.See this Section.
2.Remove 4 nuts securing tail door lock.
3.Partially withdraw lock assembly, carefully
disconnect central door locking rod from fulcrum
arm.
4.Remove lock assembly.
5.Remove door lock gasket.
NOTE: Do not carry out further
dismantling if component is removed for
access only.
6.Insert key in lock, depress lock barrel plunger
and withdraw barrel from lock.Refit
7.Fit new barrel to lock.
8.Fit new door lock gasket.
9.Fit door locking rod to fulcrum, align lock. Fit and
tighten nuts to10 Nm (7 lbf.ft ).
10.Close door and check for correct latching with
striker. Adjust striker if necessary.See
Adjustment.
11.Fit tail door trim casing.See this Section.
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