Defender (1999-2002). Manual — part 94
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CHASSIS AND BODY
5
REPAIR
13. Remove 4 bolts securing radiator mounting
bracket to wing.
14. Loosen screw and release bonnet lock inner
cable from bonnet lock.
15. Release bonnet lock outer cable from from
bonnet lock.
16. Push centre pins from studs securing wheel arch
extension to wing, remove studs and remove
wheel arch extension.
17. Remove bolt securing inner and outer wing to
chassis.
18. Remove nut and bolt securing support stay to
wing.
19. Remove 4 bolts securing wing to ’A’ post.
20. Remove bolt securing wing to bulkhead.
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76
CHASSIS AND BODY
6
REPAIR
21. Disconnect headlamp, side lamp, repeater and
indicator multiplugs.
22. With assistance, remove wing.
23. Remove bolt, remove grille support bracket.
24. Remove 4 screws securing side and indicator
lamps.
25. Remove 2 screws securing headlamp finisher to
wing, remove finisher.
26. Remove 4 screws and remove headlamp from
wing, collect sealing ring.
27. Release side repeater lamp from wing.
28. Remove bonnet cable grommet.
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CHASSIS AND BODY
7
REPAIR
Refit
29. Fit bonnet cable grommet.
30. Fit side repeater lamp to wing.
31. Fit headlamp sealing ring, fit headlamp and
tighten screws.
32. Fit headlamp finisher, side and indicator lamps
and tighten screws.
33. Fit grille support bracket and tighten bolt.
34. With assistance, position and align wing to body
and locate bonnet cable to wing.
35. Connect headlamp, indicator, side lamp and side
repeater lamp multiplugs.
36. Fit bolt securing wing to bulkhead.
37. Fit bolts securing wing to ’A’ post.
38. Fit nut and bolt securing support stay to wing.
39. Fit bolt securing inner and outer wing to chassis.
40. Fit bolts securing radiator bracket to wing.
41. Fit bolts securing outer wing to inner wing.
42. Align wing and finally tighten all bolts.
43. Position wheel arch extension to wing, and fit
securing studs.
44. Position PAS reservoir to wing and tighten bolts.
45. Position expansion tank pipe and secure with
studs.
46. Position EGR solenoid and tighten bolts.
47. Position heater air intake seal and fit air intake.
48. Fit heater air intake bracket and tighten bolts.
49. Fit heater air intake grille and tighten screws.
50. Align air cleaner intake elbow, tighten screws
and fit grille.
51. Fit wheel arch liner. See this Section.
52. Position bonnet release cable to lock and tighten
screw.
53. Fit cooling fan cowl.
54. Fit front grille. See this Section.
STEP - FOLDING - REAR DOOR
Service repair no - 76.10.41
Remove
1. Remove 2 bolts securing step to chassis
member, remove step and collect spacers.
Refit
2. Position step, fit spacer washers and tighten
bolts.
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76
CHASSIS AND BODY
8
REPAIR
LINER - FRONT WHEEL ARCH
Service repair no - 76.10.48
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove front wheel.
3. Support axle weight with jack.
4. Remove 6 screws securing damper top cover to
inner wing, remove cover.
5. Remove nut securing damper to top mounting
bracket and collect rubber bush and 2 washers.
6. Remove 4 nuts securing damper to mounting
bracket and collect washers.
7. Remove damper top cover.
8. Remove 4 screws and 3 studs securing liner to
inner wing. Remove liner.
Refit
9. Position liner, secure with screws and studs.
10. Fit damper mounting bracket and tighten nuts.
11. Position damper to mounting bracket, fit rubber
bush and washers and tighten nut.
12. Fit damper cover to inner wing and secure with
screws.
13. Fit road wheel.
14. Remove stands and lower vehicle.
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