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

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2
REPAIR STARTER MOTOR
Service repair no - 86.60.01
Remove
1.Remove battery cover.
2.Disconnect battery negative lead.
3.Remove fixings and remove underbelly panel.
4.Disconnect Lucar from starter solenoid.
5.Remove nut and disconnect battery lead from
starter solenoid.
6.Remove nut and 2 bolts securing starter to
gearbox housing. Remove starter.
Refit
7.Clean starter motor and mating face.
8.Position starter and tighten nut and 2 bolts to27
Nm (20 lbf.ft)
9.Connect lead to starter solenoid and tighten nut.
10.Connect Lucar to starter solenoid.
11.Fit underbelly panel.
12.Reconnect battery negative lead.
13.Fit battery cover.CENTRE HIGH MOUNTED STOP LIGHT (CHMSL) -
UP TO 02MY
Service repair no - 86.41.32
Remove
1.Remove 2 screws securing lamp cover.
2.Remove lamp cover.
3.Disconnect 2 Lucars from bulb holder.
4.Remove 2 nuts securing lamp to tail door.
5.Remove lamp.
6.Collect gasket.
Refit
7.Position gasket.
8.Position lamp.
9.Secure lamp with nuts.
10.Connect Lucars to bulb holder.
11.Fit lamp cover.
12.Secure cover with screws. 
						

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REPAIR ALTERNATOR
Service repair no - 86.10.02
Remove
1.Remove auxilliary drive belt.See this Section.
2.Release cover and remove nut securing lead to
alternator.
3.Disconnect alternator multiplug.
4.Remove bolt (LH thread) and remove auxiliary
drive belt tensioner.
5.Remove bolt securing support stay to alternator.
6.Release clip securing lubrication drain hose to
vacuum pump.
7.Loosen vacuum pump lubrication pipe from
cylinder head and discard’O’ring.
8.Remove bolt securing alternator and release
from mounting bracket.
9.Disconnect hose from vacuum pump.
10.Remove alternator taking care not to damage
radiator cooling fins.
11.Remove 4 bolts, and remove vacuum pump from
alternator.
CAUTION: Plug the connections. 
						

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REPAIR Refit
12.Clean mating face of alternator and vacuum
pump.
13.Fit vacuum pump to alternator and tighten bolts
to10 Nm (7 lbf.ft).
14.Position alternator and connect multiplug.
15.Connect vacuum hose and oil drain hose to
vacuum pump and secure clip.
16.With assistance align alternator to mounting
bracket and fit but do not tighten bolt.
17.Fit bolt securing support stay to alternator and
tighten to25 Nm (18 lbf.ft).
18.Tighten alternator to mounting bracket bolt to45
Nm (33 lbf.ft).
19.Using new’O’ring, fit and tighten lubrication pipe
union to10 Nm (8 lbf.ft).
20.Connect lead to alternator and tighten nut to6
Nm (4.4 lbf.ft).
21.Fit auxilliary drive belt tensioner and tighten bolt
to50 Nm (37 lbf.ft).
22.Fit auxilliary drive belt.See this Section.HORN - LH
Service repair no - 86.30.10
Remove
1.Remove LH headlamp.See this Section.
2.Disconnect horn multiplug.
3.Remove nut and remove horn from mounting
bracket.
Refit
4.Position horn, tighten securing and connect
multiplug.
5.Fit LH headlamp.See this Section. 
						

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REPAIR HEADLAMP
Service repair no - 86.40.49
Remove
1.Remove 4 screws and release side and indicator
lamps from wing.
2.Disconnect multiplugs and remove side and
indicator lamps.
3.Remove 2 screws and remove headlamp
finisher.
4.Remove 4 screws securing headlamp to wing,
disconnect multiplugs and remove headlamp.
5.Remove headlamp seal.Refit
6.Fit headlamp seal.
7.Position headlamp, connect multiplugs, fit and
tighten headlamp screws.
8.Fit headlamp finisher and secure with screws.
9.Position side and indicator lamps, connect
multiplugs and secure with screws.
10.Reset headlamp alignment.See Adjustment. 
						

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REPAIR LAMP - TAIL
Service repair no - 86.40.70
Remove
1.Remove 2 screws securing tail lamp to body.
2.Disconnect multiplug and remove lamp.
Refit
3.Position tail lamp and connect multiplug.
4.Fit and tighten lamp securing screws.RADIO
Service repair no - 86.50.03
Remove1.Using toolSMD 4091release radio from cage.
2.Disconnect coaxial cable from radio.
3.Disconnect 2 multiplugs from radio.
4.Remove radio from fascia.
Refit
5.Position radio to fascia and connect multiplugs.
6.Connect coaxial cable to radio.
7.Secure radio in cage. 
						

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REPAIR SPEAKER - FRONT
Service repair no - 86.50.15
Remove
1.Remove 4 screws securing speaker to fascia.
2.Release speaker from fascia and disconnect 2
Lucars.
3.Remove speaker.
Refit
4.Position speaker to fascia and connect Lucars.
5.Fit speaker to fascia and secure with screws.SWITCH - TRANSMISSION BRAKE
Service repair no - 86.65.45
Remove1.Release cover from transmission brake lever.
2.Remove 2 bolts and release transmission brake
lever from body.
3.Disconnect Lucar from transmission brake
warning switch.
4.Remove 2 screws securing switch from brake
lever and remove switch.
Refit
5.Fit switch to brake lever and tighten screws.
6.Connect switch Lucar.
7.Position brake lever and tighten bolts to22 Nm
(16 lbf.ft).
8.Position cover to brake lever. 
						

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REPAIR LAMP - FRONT FLASHER
Service repair no - 86.40.42
Remove
1.Remove 2 screws securing flasher lamp to front
wing.
2.Disconnect multiplug and remove lamp.
Refit
3.Position flasher lamp and connect multiplug.
4.Fit and tighten lamp securing screws.BATTERY - DISCONNECT - FROM 02MY
Service repair no - 86.15.99
Remove
1.Remove front seat cushion.
2.Release clip and remove battery cover.
3.Loosen bolt securing negative earth lead, do not
remove lead at this stage.
4.Fit ignition key, turn to position’II’. Turn ignition
off, remove key from lock and immediately
remove negative lead.
Refit
5.Connect negative lead to negative terminal and
tighten bolt to10 Nm (7 lbf.ft).
6.Fit and secure battery cover.
7.Fit seat cushion. 
						

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REPAIR MOTOR & REGULATOR - FRONT DOOR - FROM
02MY
Service repair no - 86.25.03
Remove
1.Remove plastic sheet.See CHASSIS AND
BODY, Repair.
2.Lower glass and remove 2 bolts securing door
glass to regulator.
3.Release glass from regulator, raise and wedge
in raised position.
4.Disconnect multiplug from motor.
5.Remove 4 bolts and 2 nuts securing motor and
regulator assembly.
6.Release and remove motor and regulator
assembly.
Refit
7.Fit motor and regulator assembly, fit nuts and
bolts and tighten to10 Nm (7 lbf.ft).
8.Connect multiplug to motor.
9.Remove wedges, lower glass and locate to
regulator. Fit bolts and tighten to6 Nm (4 lbf.ft).
10.Raise and lower glass to check operation.
11.Fit plastic sheet.See CHASSIS AND BODY,
Repair. 
						

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REPAIR SWITCH - FASCIA - FROM 02MY
Service repair no - 86.25.18
Remove
1.Remove radio.See this Section.
2.Release switch, disconnect multiplug and
remove switch.
Refit
3.Connect multiplug to switch and fit switch to
panel.
4.Fit radio.See this Section.HARNESS - FRONT DOOR - FROM 02MY
Service repair no - 86.25.20
Remove
1.Remove door lock solenoid.See this Section.
2.Carefully peel back section of plastic sheet for
access to harness.
3.Release clips securing harness to panel.
4.Disconnect multiplug from motor.
5.Release harness sleeve and withdraw harness
from door.
6.Release harness sleeve and withdraw harness
multiplugs from’A’post.
7.Disconnect 2 multiplugs and remove harness. 
						

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REPAIR Refit
8.Position harness and connect multiplugs.
9.Feed multiplugs into’A’post and secure harness
sleeve.
10.Connect multiplug to motor.
11.Secure harness clips and sleeve.
12.Secure plastic sheet.
13.Fit door lock solenoid.See this Section.SOLENOID/MOTOR - TAIL DOOR - FROM 02MY
Service repair no - 86.26.02
Remove
1.Remove tail door trim casing.See CHASSIS
AND BODY, Repair.
2.Disconnect multiplug from solenoid.
3.Remove bolt and screw securing solenoid to
door.
4.Release clip securing harness to solenoid
mounting bracket.
5.Remove solenoid assembly from operating rod.
6.Remove 2 screws securing solenoid to mounting
bracket.