1999 LAND ROVER DEFENDER battery

BRAKES
1
ADJUSTMENT BRAKE SYSTEM BLEED
Service repair no - 70.25.02
Preparation
WARNING: Before bleeding the brake
system refer to general brake service
practice.See this Section. general brake
service practice
During bleed procedure, brake fluid level must
not be allowed to fall below the MIN mark. Keep
reservoir topped up to the MAX mark.
To bleed the hydraulic circuits, four bleed
nipples are provided, one at each caliper.
There are two methods by which air can be removed
from the braking system:-
1.MANUAL BLEED PROCEDURE
2.PRESSURE BLEED PROCEDURE
Pressure bleed procedure
Purpose designed equipment for pressure filling and
bleeding of hydraulic systems may be used on Land
Rover vehicles. The equipment manufacturers
instructions must be followed and the pressure must
not exceed 4.5 bar, 65 lb/in.
Manual bleed procedure
Equipment required
Clean glass receptacle
Bleed hose
Wrench
Approx. 2 litres (3 pts) brake fluid
Master cylinder bleed
1.Disconnect battery negative lead.
2.Depress brake pedal fully and slowly 5 times.
3.Release pedal and wait 10 seconds.
4.Repeat until firm resistance is felt at the pedal.Complete circuit bleed
1.Disconnect battery negative lead.
2.Fit bleed hose to caliper bleed screw.
3.Dip free end of bleed hose into brake fluid in
bleed bottle.
4.Open bleed nipple.
5.Depress brake pedal fully several times until fluid
is clear of air bubbles.
6.Keeping pedal fully depresses, tighten bleed
nipple then release pedal.
7.Repeat procedure for remaining calipers.
8.Fit bleed screw protection caps.
9.Check/top-up fluid level when bleeding is
complete.
ProCarManuals.com

BRAKES
1
REPAIR ECU - ABS
Service repair no - 70.65.01
Remove
1.Disconnect battery negative lead.
2.Release and remove passenger seat base.
3.Release clip securing ECU cover plate.
4.Remove ECU cover plate.
5.Disconnect 3 multiplugs from ABS ECU.
6.Disconnect 2 multiplugs from engine
management ECU.
7.Release seat base carpet to gain access to ECU
mounting plate Torx screws.
8.Remove 2 Torx screws securing front edge of
ECU mounting plate.
9.Remove nut securing rear edge of ECU
mounting plate.
10.Remove mounting plate and ECU assembly from
seat base.
11.Remove 3 bolts securing ABS ECU to mounting
plate.
12.Remove ABS ECU.
Refit
13.Position ABS ECU to mounting plate and secure
with bolts.
14.Fit mounting plate and ECU assembly to seat
base.
15.Fit Torx screws and nut securing mounting plate
to seat base.
16.Re-position carpet.
17.Connect multiplugs to ABS and engine
management ECU’s.
18.Fit ECU cover plate to seat base and secure in
position with clip.
19.Fit passenger seat base.
20.Reconnect battery negative lead.
ProCarManuals.com

70BRAKES
4
REPAIR MASTER CYLINDER
Service repair no - 70.30.08
Remove
1.Disconnect battery negative lead.
2.Place a container under the master cylinder to
collect any brake fluid spillage.
CAUTION: Do not allow brake fluid to
contact paint finished surfaces as paint
may be damaged. If spilled, remove fluid
and clean area with clean warm water.
3.Clean area around master cylinder ports.
4.Loosen 2 unions securing brake pipes to master
cylinder ports.
5.Disconnect both brake pipes from master
cylinder. Cover, not plug, pipe ends to prevent
entry of dirt.
6.Disconnect 2 Lucars from reservoir cap.
7.Remove 2 nuts securing master cylinder to
brake servo.
8.Withdraw master cylinder from servo and
remove.
Do not carry out further dismantling if
component is removed for access only.9.Carefully ease reservoir from master cylinder by
rolling it from seals.
10.Remove seals from master cylinder.
NOTE: Master cylinder to reservoir seals
are different sizes.
11.Fit NEW seals to master cylinder, ensuring seals
are fitted to correct ports.
12.Fit reservoir to master cylinder.
Refit
13.Ensuring that water ingress seal is in position, fit
master cylinder to servo.
14.Fit nuts securing master cylinder to servo and
tighten to26 Nm (19 lbf.ft).
15.Connect brake pipes to master cylinder and
tighten unions to15 Nm (11 lbf.ft).
16.Connect Lucars to reservoir cap.
17.Fill reservoir with recommended brake fluid.See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
18.Bleed the brake system.See Adjustment.
19.Reconnect battery negative lead.
ProCarManuals.com

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.
ProCarManuals.com

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.
ProCarManuals.com

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.
ProCarManuals.com

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.
ProCarManuals.com

76CHASSIS AND BODY
36
REPAIR LOWER FASCIA PANEL - FROM 02MY
Service repair no - 76.46.05
Service repair no - 80.10.12
NOTE: This procedure also covers
removal of the air distribution control
cable, 80.10.12.
Remove
1.Disconnect battery negative lead.See
ELECTRICAL, Repair.
2.Remove steering column nacelle.See
STEERING, Repair.
3.Remove fascia console.See this Section.
4.Remove air vent control knobs.
5.Remove 6 screws, remove fascia closing panel
and collect nut plate.
6.Remove speakers.See ELECTRICAL, Repair.
7.Remove 2 screws and remove both door check
strap covers.
8.Remove 3 screws and remove end cap from
lower fascia panel.
9.Loosen grub screw and clamp plate bolt
securing air distribution cable. Release cable
from control lever.
10.Release screen demister tubes from lower fascia
panel.
ProCarManuals.com