Land Rover Defender 1999 2002my Workshop Supplement Body Repair 3rd Edition Rover Manual

							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. 
						

							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. 
						

							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. 
						

							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. 
						

							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. 
						

							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. 
						

							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. 
						

							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. 
						

							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. 
						

							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.