1999 LAND ROVER DEFENDER battery

CHASSIS AND BODY
37
REPAIR
11.Remove 2 screws securing fuse cover and
remove cover.
12.Remove 7 screws securing lower edge of fascia
panel.
13.Remove footwell cover retaining plates.
14.Remove 2 nuts and remove lower fascia panel.
NOTE: Do not carry out further
dismantling if component is removed for
access only.
15.Remove 21 screws and release air duct cover.
16.Loosen trunnion screw, remove air distribution
cable and duct cover.Refit
17.Fit air distribution cable to duct cover and fit
inner cable to vent flap trunnion.
18.Tighten vent flap trunnion screw to6Nm(4
lbf.ft)and bend cable end to secure.
19.Fit duct cover to lower fascia and fit and tighten
screws.
20.Check condition of seal between heater and
lower fascia, if damaged replace.
21.Carefully fit lower fascia panel and ensure
harness route is correct.
22.Secure lower fascia panel with screws and
tighten nuts to10 Nm (7 lbf.ft).
23.Fit fuse cover and secure with screws.
24.Connect demister tubes to lower fascia panel.
25.Raise air distribution lever to screen demist
position and close footwell vent.
26.Connect air distribution cable to lever, tighten
grub screw and outer cable clamp.
27.Fit end cap to fascia and secure with screws.
28.Fit check strap covers and secure with screws.
29.Fit speakers.See ELECTRICAL, Repair.
30.Fit fascia closing panel.
31.Fit nut plate and fit screws to secure nut plate
and closing panel.
32.Fit knobs to air vent control levers.
33.Fit fascia console.See this Section.
34.Fit steering column nacelle.See STEERING,
Repair.
35.Connect battery negative lead.See
ELECTRICAL, Repair.
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77PANEL REPAIRS
28
SEALING AND CORROSION PROTECTION WATER LEAKS
Sealing charts in this section show those areas of the
bodyshell most likely to be affected by accident
damage and water leaks, and which could therefore
require re-treatment in repair. They do not show those
joint areas which only apply to factory assembly
operations and which are unlikely to be disturbed in
service (e.g. centre tunnel), or where the damage
would be so severe that the entire bodyshell would
normally be written off.
When water leakage occurs, always adopt a logical
approach to the problem using a combination of skill,
experience and intuition. Do not attempt to reach a
conclusion based only on visual evidence, such as
assuming that a leak emanates from the windscreen
because the footwell is wet. It will often be found that
the source of the leak is elsewhere. The correct
procedure will increase the chance of locating a leak,
however obscure it may seem.
Tools and Equipment
The following tools and equipment are recommended
for detection and rectification of water leaks:
1. Garden sprayer (hand-operated).
2. Wet/dry vacuum cleaner.
3. Dry absorbent cloths.
4. Battery torch.
5. Small mirror.
6. Weatherstrip locating tool.
7. Trim panel remover.
8. Small wooden or plastic wedges.
9. Dry compressed air supply.
10. Hot air blower.
11. Sealer applicators.
12. Ultrasonic leak detector.
During leak detection, the vehicle should be
considered in three basic sections:
The front interior space,
The rear passenger space (where
applicable), and
The rear loadspace or boot.Testing
From the information supplied by the customer it
should be possible for the bodyshop operator to locate
the starting point from which the leak may be
detected. After the area of the leak has been
identified, find the actual point of entry into the vehicle.
A simple and effective means initially is an ordinary
garden spray with provision for pressure and jet
adjustment. This will allow water to be directed in a jet
or turned into a fine spray. Use a mirror and a
battery-powered torch (NOT a mains voltage
inspection lamp) to see into dark corners.
The sequence of testing is particularly important. Start
at the lowest point and work slowly upwards, to avoid
testing in one area while masking the leak in another.
For example, if testing started at the level of the
windscreen, any water cascading into the plenum
chamber could leak through a bulkhead grommet and
into the footwells. Even at this point it could still be
wrongly assumed that the windscreen seal was at
fault.
Another important part of identifying a water leak is by
visual examination of door aperture seals, grommets
and weatherstrips for damage, deterioration or
misalignment, together with the fit of the door itself
against the seals.
Sealing
When the point of the leak has been detected,
proceed to rectify it using the following procedure:
1. Renew all door aperture seals and weatherstrips
which have suffered damage, misalignment or
deterioration.
2. Check all body seals to ensure that they are
correctly located on their mounting flanges/faces
using a locating tool if necessary.
3. Dry out body seams to be treated using
compressed air and/or a hot air blower as
necessary.
4. Apply sealant on the outside of the joint
wherever possible to ensure the exclusion of
water.
5. When rectifying leaks between a screen glass
and its weatherstrip (or in the case of direct
glazing, between the glass and bodywork), avoid
removing the glass if possible. Apply the
approved material either at the glass to
weatherstrip or glass to body.
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PANEL REPAIRS
1
REPAIR WING LOWER FRONT
Remove
1.Disconnect both battery leads, negative lead
first. system.
2.Remove wheel arch eyebrow.
3.Remove wheel arch liner.
4. RH side:Remove aerial.
5.Remove air intake hose.
6.Remove bolts securing lower wing.
Refit
7.Prepare and clean panel joint faces.
8.Reverse removal procedure.HEADLAMP MOUNTING PANEL
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect all ECUs.
3.Remove radiator.See COOLING SYSTEM,
Repair.
4.Recover refrigerant from A/C system.See AIR
CONDITIONING, Repair.
5.Remove headlamp.See ELECTRICAL,
Repair.
6. LH side:Remove screen washer bottle.See
WIPERS AND WASHERS, Repair.
7. RH side:Position PAS reservoir aside.
8.Remove bolts and release welds securing panel,
remove panel.
Refit
9.Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding as
shown.
10.Reverse removal procedure.
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77PANEL REPAIRS
2
REPAIR WING UPPER - LH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove headlamp.See ELECTRICAL,
Repair.
3.Remove headlamp mounting panel.See this
Section.
4.Remove radiator.See COOLING SYSTEM,
Repair.
5.Recover refrigerant from A/C system.See AIR
CONDITIONING, Repair.
6.Remove receiver drier.See AIR
CONDITIONING, Repair.
7.Remove relevant A/C pipes.
8.Remove relevant heater intake pipes.
9.Remove screen washer bottle.
10.Remove wheel arch liner.See CHASSIS AND
BODY, Repair.
11.Remove bolts and release welds securing panel,
remove panel.
Refit
12.Prepare and clean panel joint faces.
13.Reverse removal procedure.
14.Align headlamps.See ELECTRICAL,
Adjustment.WING UPPER - RH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove headlamp.See ELECTRICAL,
Repair.
3.Remove headlamp mounting panel.See this
Section.
4.Remove radiator.See COOLING SYSTEM,
Repair.
5.Recover refrigerant from A/C system.See AIR
CONDITIONING, Repair.
6.Remove relevant A/C pipes.
7.Position PAS reservoir aside.
8.Remove wheel arch liner.See CHASSIS AND
BODY, Repair.
9.Remove aerial.
10.Remove vacuum solenoid valve.
11.Release clips securing coolant reservoir.
12.Remove bolts and release welds securing panel,
remove panel.
Refit13.Prepare and clean panel joint faces.
NOTE: LH panel shown
14.Reverse removal procedure.
15.Align headlamps.See ELECTRICAL,
Adjustment.
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PANEL REPAIRS
3
REPAIR WHEEL ARCH - FRONT
Remove
The procedure to change the Inner Front Wheelarch is
the same as for the Wing Upper, except for removal of
the ABS sensors and shield, if fitted.
BULKHEAD ASSEMBLY
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove front lower wing.See this Section.
3.Remove RH and LH front upper wing.See this
Section.
4.Remove headlamp mounting panels.See this
Section.
5.Remove screen aperture.See this Section.
6.Remove both front doors.
7.Remove lower fascia panel.See CHASSIS
AND BODY, Repair.
8. Models with A/C:Remove relevant A/C pipes.
9.Remove front grille.
10.Drain cooling system.See COOLING
SYSTEM, Adjustment.
11.Remove radiator and intercooler.
12. Models with A/C:Remove condensor.
13.Remove air cleaner assembly.
14.Remove heater unit.See HEATING AND
VENTILATION, Repair.
15.Remove brake servo assembly.
16.Remove heater ducts.
17.Remove both front seats.
18.Remove front carpets.
19.Release all relevant harnesses and position
aside.
20.Remove facia support bracket.
Refit
21.Prepare and clean panel joint faces. Ensure all
necessary grommets and sealant is applied to
new bulkhead.
22.Reverse removal procedure.
23.Bleed brake system.See BRAKES,
Adjustment.
24.Align headlamps.See ELECTRICAL,
Adjustment.
25.Water test after refitting.
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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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PANEL REPAIRS
5
REPAIR SILL - FRONT
Remove
NOTE: The procedure to replace the rear
sill section is the same as the front.
1.Remove bolts securing sill to body, discard seal.
Refit
NOTE: Front sill
NOTE: Rear sill
2.Prepare and clean panel joint faces. Refit new
seal.
3.Reverse removal procedure.’B/C’&’D’POST
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove rear door and striker.
3.Remove front seat belt reel.See CHASSIS
AND BODY, Repair.
4.Remove front and rear carpets.
5.Remove front seat.
6.Remove rear seat.
7.Remove front, centre and rear sections of
headlining.
NOTE: Assembly is held on with bolts.
Refit
8.Prepare and clean panel joint faces.
9.Reverse removal procedure.
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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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