Defender (1999-2002). Manual — part 116
77
PANEL REPAIRS
6
PROCEDURES
REPAIR PROCEDURES
Body Trim
The following panel repair operations itemise body
trim components which must be removed for access
during each repair. See Repairs section.
Because of the unpredictable nature of accident
damage, the items listed make no allowance for any
difficulties which may be found in removal and only
apply to an undamaged vehicle. No allowance is
made for any difficulties which may be found during
panel removal. Damaged body trim items must be
renewed as necessary following body repairs.
![](/vehicles/onond/ycatth/que/knst.png)
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.
![](/vehicles/onond/ycatth/que/chear.png)
77
PANEL 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.
Refit
13. Prepare and clean panel joint faces.
NOTE: LH panel shown
14. Reverse removal procedure.
15. Align headlamps. See ELECTRICAL,
Adjustment.
![](/vehicles/onond/ycatth/que/weackno.png)
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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