1999 LAND ROVER DEFENDER battery

PANEL REPAIRS
7
REPAIR BODY SIDE REAR - LOWER - ASSEMBLY
In this procedure the Body Side Capping and the
Corner Capping are also changed.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove body side upper rear.See this
Section.
3.Remove all rear lamps and reflectors.
4. LH side:Remove number plate and lamp.
5. LH side:Remove tail door striker.
6. RH side:Remove fuel filler and grommet.
7.Remove all bolts and rivets securing lower body
side assembly.
Refit
8.Prepare and clean panel joint faces.
9.Reverse removal procedure.
NOTE: When refitting, ensure body side
upper is correctly fitted onto location pins.
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77PANEL REPAIRS
8
REPAIR BODY SIDE REAR - PANEL
Remove
In this procedure the Body Side Capping and the
Corner Capping are also changed.
1.Disconnect both battery leads, negative lead
first.
2.Remove body side upper rear.See this
Section.
3.Remove rear lamp panel.See this Section.
4. LH side:Remove number plate and lamp.
5. LH side:Remove tail door striker.
6. RH side:Remove fuel filler and grommet.
Refit
7.Prepare and clean panel joint faces. Drill holes in
new body side lower panel for riveting. Spacing
of holes, dimension’A’= 100 mm (3.937’). In
conjunction with the rivets apply suitable
adhesive.
8.Prepare and clean panel joint faces.
9.Reverse removal procedure.
NOTE: When refitting, ensure body side
upper is correctly fitted onto location pins.
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PANEL REPAIRS
9
REPAIR REAR LAMP PANEL
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect alternator.
3.Remove rear bench seat.
4. RH side:Remove tail door.See CHASSIS
AND BODY, Repair.
5.Remove rear lights and reflector.
6. LH side:Remove number plate and tail door
striker.
Refit
7.Prepare and clean panel joint faces.
8.Reverse removal procedure.REAR CROSSMEMBER PANEL
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove both rear lamp panels.See this
Section.
Refit
3.Prepare and clean panel joint faces.
4.Reverse removal procedure.
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77PANEL REPAIRS
10
REPAIR ROOF ASSEMBLY
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove rear bench seats.
3.Remove front, centre and rear sections of
headlining.
4.Remove all bolts securing roof.
NOTE: Carefully cut sealant securing front
edge of roof to windscreen aperture.
Refit
5.Prepare and clean panel joint faces.
6.Reverse removal procedure.
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82AIR CONDITIONING
4
REPAIR EVAPORATOR
Service repair no - 82.25.20
Remove
1.Remove battery cover.
2.Recover refrigerant from A/C system.See
Adjustment.
3.Remove 2 bolts securing A/C pipes to
evaporator.
4.Release pipes and discard’O’rings.
CAUTION: Immediately cap all air
conditioning pipes to prevent ingress of
dirt and moisture into the system.
5.Remove 2 screws and release fuse/relay bracket
from body and collect 2 spacers.
6.Remove 8 screws securing speakers to A/C
duct.
7.Disconnect speaker Lucars and remove
speakers.
8.Remove 4 screws and bolt securing A/C duct to
fascia panel.
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WIPERS AND WASHERS
3
REPAIR WIPER MOTOR AND DRIVE RACK - FROM 02MY
Service repair no - 84.15.09
Remove
1.Disconnect battery negative lead.See
ELECTRICAL, Repair.
2.Remove wiper arms.See this Section.
3.Remove fascia console.See CHASSIS AND
BODY, Repair.
4.Remove air vent control knobs.
5.Remove 6 screws, remove fascia closing panel
and collect nut plate.
6.Move cover aside and loosen wiper motor drive
tube nut.
7.Remove 2 screws securing wiper motor, remove
retaining strap and mounting pad.
8.Disconnect multiplug from wiper motor.
9.Remove tube nut and remove wiper motor with
rack.
Refit
10.Lubricate wiper motor drive rack with grease.
11.Feed wiper motor rack into tube, connect
multiplug and fit but do not tighten tube nut.
12.Fit mounting pad and retaining strap, align wiper
motor and tighten screws.
13.Tighten wiper motor tube nut to8 Nm (6 lbf.ft)
and reposition nut cover.
14.Fit fascia closing panel.
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84WIPERS AND WASHERS
4
REPAIR 15.Fit nut plate and fit screws to secure nut plate
and closing panel.
16.Fit knobs to air vent control levers.
17.Fit fascia console.See CHASSIS AND BODY,
Repair.
18.Fit wiper arms.See this Section.
19.Connect battery negative lead.See
ELECTRICAL, Repair.WHEELBOX/DRIVE PIVOT - FROM 02MY
Service repair no - 84.15.25
Remove
1.Disconnect battery negative lead.See
ELECTRICAL, Repair.
2.Remove steering column nacelle.See
STEERING, Repair.
3.Remove wiper motor and drive rack.See this
Section.
4.Remove 2 screws and move heater fan switch
aside.
5.Remove 2 screws securing drivers side demister
duct.
6.Disconnect demister tube and remove duct.
7.Remove bolt and nut and bolt securing steering
column support bracket and remove bracket.
8.Remove 11 screws securing fascia support rail.
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WIPERS AND WASHERS
5
REPAIR
9.Remove cable ties securing washer tube to
windscreen wiper rack tube.
10.Loosen fully 4 nuts securing backplates to wheel
boxes and remove windscreen wiper rack tubes.
11.Remove seals from wheel box spindles.
12.Remove 2 nuts securing wheel boxes and
remove sealing washers.
13.Carefully pull fascia support rail from bulkhead
sufficiently to remove wheel boxes.
Refit
14.Loosen fully but do not remove nuts securing
wheel box back plates.
15.Grease wheel boxes.
16.Fit wheel boxes, fit sealing washers and tighten
nuts to5 Nm (3.7 lbf.ft).
17.Fit spindle seals.
18.Fit wiper rack tubes and tighten wheel box back
plate nuts sufficiently to hold tubes. Tighten
wheel box back plate nuts to6 Nm (4 lbf.ft)
after fitting windscreen wiper motor.
19.Align washer tube to rack tube and secure with
cable ties.
20.Align fascia support rail and secure with screws.
21.Fit steering column support bracket and tighten
bolt and nut and bolt to45 Nm (33 lbf.ft).
22.Fit demister duct to tube, align relay bracket and
secure duct with screws.
23.Position heater fan switch and secure with
screws.
24.Fit wiper motor and drive rack.See this
Section.
25.Fit steering column nacelle.See STEERING,
Repair.
26.Connect battery negative lead.See
ELECTRICAL, Repair.RELAY - WIPER DELAY - FROM 02MY
Service repair no - 84.15.37
Remove
1.Disconnect battery negative lead.See
ELECTRICAL, Repair.
2.Remove 4 screws securing instrument pack and
release pack from fascia.
3.Disconnect 2 multiplugs from warning lamp
panel.
4.Disconnect instrument pack multiplug from main
harness.
5.Remove instrument pack.
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