Land Rover Defender: Installation

1.

NOTE: Complete install step 2 to 5 before tightening the 8 armature bolts.

Loosen the 8 armature bolts to assist the installation of the front undershield support bar (A1).

2.

NOTE: This step requires the aid of another technician.

Align and install the front undershield support bar (A1).

1. Align the front undershield support bar with the vehicle.
2. Align the ends of the front undershield support bar with the brackets as illustrated.
3. Make sure the holes for the bolts (S5) align with the holes in the subframe. Adjust the armature position to achieve correct hole alignment.
4. Install, but do not fully tighten the 2 M12 bolts (S5) to secure the front undershield support bar to the vehicle.

3.

CAUTION: Make sure the air conditioning pipes are positioned correctly on both sides of the front undershield support bar.

NOTE: This step requires the aid of another technician.

Secure the ends of the front undershield support bar.

1. Check the alignment of the front undershield support bar with the bracket as illustrated.
2. Install, but do not fully tighten the 2 bolts (C1) to secure the front undershield support bar to the bracket.
3. Make sure the air conditioning pipes on both sides of the front undershield support bar are installed in the correct location.

4.

CAUTION: On P6 vehicle variants there is a cooling pipe that must be installed to the front undershield support bar.

Install the clips (S4) and correctly position the cooling pipe.

1. Install the 2 clips (S4) to the front undershield support bar.
2. Install the cooling pipe to the 2 arrowed clips and position the cooling pipe as required.

5. Tighten the bolts (S5) and (C1).

• Torque: 60 Nm

6.

CAUTION: Tighten the 8 armature bolts that were loosened during install step 1.

Tighten the 8 armature bolts.

• Torque: 55 Nm

7.

Install the 2 brake ducts to the front undershield support bar using the 4 fixings (S3).

8.

NOTE: At this stage the front bumper carrier is still removed from the vehicle.

Install the 8 rivet nuts (U) to the lower corners of the front bumper carrier. Follow the process below or use a rivet nut fastening tool.

1. Install a M6 bolt (V) to each of the rivet nuts (U).
2. Tighten each M6 bolt (V) to collapse the rivet nut it is installed into.
3. Remove all the M6 bolts (V) and retain.

9.

NOTE: Install, but do not fully tighten the 4 bolts (D).

Install the 2 lower brackets (L) to the front bumper carrier using the 4 bolts (D), the 8 washers (S) and the 4 nuts (T).

• Install, but do not fully tighten the 4 bolts (D).

10.

Position the A-frame carrier (A) onto the front bumper carrier and make sure the 2 brackets (L) are positioned correctly.

1. Make sure the 4 arrowed cutouts in the A-frame carrier (A) are positioned correctly over the brackets (L) on both sides of the front bumper carrier.
2. If required adjust the position of the brackets (L).

11. Remove the A-frame carrier (A) from the front bumper carrier.

12.

Tighten the 4 bolts (D) that secure the 2 lower brackets (L) to the front bumper carrier.

• Torque: 12 Nm

13.

Install the 2 modified front bumper lower corner covers to the corners of the front bumper carrier.

1. Install parking aid sensors that were previously removed.
2. Connect the parking aid sensors. The quantity of parking aid sensors will vary depending on the vehicle specification.

14.

Feed the camera harness through the illustrated hole in the grille part of the front bumper carrier. This is the hole to the side of the hole previously used by the camera.

• The camera harness must be accessible from the front of the bumper carrier.

15.

CAUTIONS:

• Care must be taken to avoid damaging the surrounding paintwork.
• Take care not to damage the camera wiring harness and the parking aid sensor harnesses during the install of the front bumper carrier.

NOTES:

• Do not install the fully assembled front bumper to the vehicle at this stage.
• This step requires the aid of another technician.

Install the front bumper carrier to the front of the vehicle.

• Install the 8 front bumper clips on both sides.
• Install the 6 lower clips to the front bumper.
• Install and tighten the upper 5 bolts to the front bumper. Torque: 3.2 Nm

16.

NOTE: Repeat this step for the other side.

Install the front bumper finisher.

• Install the 7 clips.

17.

NOTE: Install, but do not fully tighten the 4 bolts (D).

Install the 2 upper brackets (E) to the front of the vehicle using the 4 bolts (D), the 8 washers (S) and the 4 nuts (T).

• Install, but do not fully tighten the 4 bolts (D).

18.

Position the A-frame carrier (A) against the front bumper and make sure the 2 brackets (E) are positioned correctly.

1. Make sure the arrowed cutouts in the A-frame carrier (A) are positioned correctly over the brackets (E) on both sides of the vehicle.
2. If required adjust the position of the brackets (E).

19. Remove the A-frame carrier (A) from the front bumper.

20.

Tighten the 4 bolts (D) that secure the 2 upper brackets (E) to the front bumper.

• Torque: 12 Nm

21.

If required install the upper grille to the radiator grille.

• Install the 10 clips.
• Install the upper grille.

22.

Install the radiator grille. Take care when installing the radiator grille over the 2 upper brackets (E).

• Install the 14 clips.
• Install the radiator grille.
• Install the 4 clips.

23.

CAUTION: For Dynamic and X-Dynamic vehicles the prepared chrome front bumper protector (VPLEB0441) must be installed.

NOTES:

• The 2 lower brackets (L) will be located in the 2 cutouts in the front bumper protector.
• Make sure the parking aid sensor harnesses are fed through the outer hole on each side of the front bumper protector.

Install the front bumper protector to the front bumper.

1. Feed the 2 center parking aid sensor harnesses through the illustrated holes in the front bumper protector.
2. Install the 20 front bumper protector clips.
3. Install and tighten the 8 screws. Torque: 4 Nm

24.

CAUTION: Take extra care not to damage the clips.

NOTE: Repeat this step for the other side.

Install the fog lamp finisher to the front bumper.

• Install the 7 clips.

25.

NOTES:

• This step requires the aid of another technician.
• Install but do not fully tighten the 8 bolts (D).

Install the A-frame carrier (A) using the 8 bolts (D) and the washers (S) to check the alignment.

1. Make sure the A-frame carrier location pin is aligned with the hole in the center of the front bumper protector.
2. Align the A-frame carrier to the 4 brackets (E) and (L).
3. Install but do not fully tighten the 8 bolts (D).

26.

Make sure the gap between the arrowed edges on the A-frame carrier (A) and the arrowed edges on the front bumper are equal on both sides of the vehicle.

27. Remove the A-frame carrier (A) from the vehicle.

28.

Install the fixings (G) to the A-frame carrier (A).

29.

Install the 14 rib locks (K) to the A-frame carrier (A).

30.

Install the 6 clips (H) to the A-frame carrier (A).

31.

NOTE: This step requires the aid of another technician.

Position the A-frame carrier (A) close to the front bumper so the location pin on the A-frame carrier is aligned with the hole drilled in the center of the front bumper bracket.

1. Feed the harness for the parking aid sensors through the arrowed holes in the A-frame carrier (A) on both sides of the vehicle.

32.

NOTE: This step requires the aid of another technician.

Install the A-frame carrier (A) using the 8 bolts (D) and the washers (S).

1. Make sure the A-frame carrier location pin is aligned with the hole in the center of the front bumper bracket.
2. Align the A-frame carrier to the 4 brackets (E) and (L).
3. Install but do not fully tighten the 8 bolts (D).

33.

Make sure the gap between the arrowed edges on the A-frame carrier (A) and the arrowed edges on the front bumper are equal on both sides of the vehicle.

34.

Tighten the 8 bolts (D).

• Torque: 12 Nm

35.

NOTE: Complete step only if required.

Prepare the A-frame cover (B) so the correct license plate plinth can be installed if required.

• Mark the location where the 2 holes should be drilled.

NOTES:

• Complete step only if installing a China market license plate plinth (VPLEB0435).
• The markings for the holes are located on the inside of the A-frame cover (B).
• Do not install the license plate plinth at this stage.

Drill 2 holes into the A-frame cover (B) at the illustrated positions. Arrowed locations are for China market license plate plinth.

• 2 mm drill bit

37.

NOTES:

• Complete step only if installing a NAS or Japan market license plate plinth (VPLEB0436).
• The markings for the holes are located on the inside of the A-frame cover (B).
• Do not install the license plate plinth at this stage.

Drill 2 holes into the A-frame cover (B) at the illustrated positions. Arrowed locations are for NAS or Japan market license plate plinth.

• 2 mm drill bit

38.

NOTES:

• Complete step only if installing a EU market license plate plinth.
• The markings for the holes are located on the inside of the A-frame cover (B).
• Do not install the license plate plinth at this stage.

Drill 2 holes into the A-frame cover (B) at the illustrated positions. Arrowed locations are for EU market license plate plinth (VPLEB0434).

• 2 mm drill bit

39.

CAUTION: In the event of damage to one or both of the front center parking aid sensors then the correct quantity of replacement ceres silver parking aid sensors (LR138717) must be used.

Install the parking aid sensors (S1) to the parking aid sensor brackets that are part of the A-frame cover (B).

40. Position the A-frame cover (B) close to the A-frame carrier (A).

41.

NOTES:

• This step requires the aid of another technician.
• The A-Frame Cover (B) must be positioned close to the A-frame carrier (A) to connect the parking aid sensor harnesses.

Connect the parking aid sensor harnesses to the parking aid sensors in the A-frame cover (B).

1. Make sure the parking aid sensor harness is accessible through the A-frame carrier (A).
2. Connect the parking aid sensor harness to the parking aid sensor on the A-frame cover (B).

42.

Make sure both of the parking aid sensors are installed correctly and the parking aid sensor harness is connected as illustrated.

43.

CAUTION: Take care to avoid damage to the parking aid sensor harnesses as the A-frame cover is installed.

Install the A-frame cover (B) to the A-frame carrier (A).

1. Apply force at all positions where clips are located.
2. Make sure all clips are fully engaged.
3. Check the alignment of the A-frame cover (B).

44.

Install the 10 bolts (F) to secure the A-frame cover (B) to the A-frame carrier (A). The bolts (F) will pass through the clips (G). Check the alignment.

• Torque: 8 Nm

45.

Install the 7 remaining rib locks (K) to the A-frame center trim (C).

46.

NOTE: If the front proximity camera will be installed then the camera mounting kit (VPLEB0437) must be used.

Install the camera bracket (J) to the A-frame center trim (C).

1. Align and locate the camera bracket (J) to the A-frame center trim (C).
2. Make sure the camera bracket is correctly installed as illustrated.
3. Install the 2 fixings (I).

47.

Install the A-frame center trim (C) to the A-frame cover (B).

1. Install the A-frame center trim top clips first and then push in the bottom clips.

48.

CAUTION: Take care when handling the camera. Avoid touching the camera lens.

Connect the front proximity camera (S2) to the camera harness.

• The camera harness will already have been fed through the grille part of the front bumper.

49.

CAUTION: Take care when handling the camera. Avoid touching the camera lens.

Install the camera housing (T) to the A-frame center trim (C).

1. Carefully install the camera (S2) into the camera housing (T).
2. Install the camera housing (T) to the camera bracket (J). Make sure the camera housing is correctly engaged into the bracket (J).
3. Secure the camera housing to the camera bracket using the screw (I).

50.

CAUTIONS:

• If the front proximity camera is installed then take care not to damage the camera as the plinth is being installed.
• Make sure the license plate plinth is installed correctly and is not distorted.

NOTES:

• Complete step only if required.
• If required order the license plate plinth depending on the vehicle market.

Install the license plate plinth to the A-frame cover (B) using 2 screws (N) and the 2 holes drilled in install steps 46 to 49.

1. China market (VPLEB0435).
2. NAS / Japan market (VPLEB0436).
3. EU market (VPLEB0434).

51.

NOTE: Complete step only if required.

Install the remaining 6 screws (N) to the license plate plinth.

1. China market.
2. NAS or Japan market.
3. EU market.

52. Install the license plate to the license plate plinth.

53.

• Install the hood latch panel finisher.
• Install the 6 clips.

54.

WARNING: Make sure to wear suitable personal protective equipment.

CAUTIONS:

• Mask the surrounding area first to protect the vehicle body.
• Allow the cleaner to dry for a minimum of 2 minutes before proceeding to the next step.

Use the supplied cleaner (Y) to clean the illustrated area of the front bumper lower corner cover.

1. Install the expedition corner cover (X) for masking purposes only.
2. Apply suitable tape to create a mask along the edges of the expedition corner cover.
3. Remove the expedition corner cover (X).
4. Use the supplied cleaner (Y) to clean a 10 mm strip from the edge of the tape.

55.

WARNING: Make sure to wear suitable personal protective equipment.

CAUTION: Allow the promoter to dry for a minimum of 5 minutes before proceeding to the next step.

Apply the supplied promoter (Z) to the illustrated area of the front bumper lower corner cover.

• Apply the promoter to a strip about 10 mm wide as illustrated.

56.

Install the expedition corner cover (X) to the left side of the vehicle.

1. Align the expedition corner cover to the lower corner cover.
2. Apply pressure to the expedition corner cover to secure the cover to the promoter.
3. Install the 2 arrowed clips, that are part of the expedition corner cover, over the front bumper carrier as illustrated.

57.

Install the screw (W) to secure the expedition corner cover (X) to the front bumper carrier.

58.

Install, but do not fully tighten the 4 bolts (V). The bolts must engage into the rivet nuts (U) installed to the front bumper carrier.

• Make sure the ends of the 4 lengths of protective strip are visible.

59.

NOTE: The install of the front section of the wheel arch liner will be completed in the following step 60.

Install the modified front section of the front wheel arch liner. At this stage only install the top 2 retained fixings (S6).

60.

Install, but do not fully tighten the 3 screws (W) and the retained fixing (S6) to secure the wheel arch liner to the expedition corner cover (X) and the front bumper carrier.

• Follow the illustrated screw install sequence.

61.

Remove the 4 lengths of protective strip from the sections of adhesive tape.

• Remove the protective strip from the adhesive tape by pulling on the arrowed ends of the protective strip.
• Follow the illustrated removal sequence.

62.

Tighten the 4 bolts (V).

• Torque: 2 Nm

63. Tighten the 4 screws (W) and the retained fixing (S6).

64. Repeat steps 54 to 63 to secure the expedition corner cover on the other side of the vehicle.

65. Make sure the expedition corner covers (X) are correctly installed to both sides of the vehicle.

66.

Install the front undershield (B1) to the front undershield support bar (A1).

1. Align the 2 front undershield hooks with the 2 holes in the front undershield support bar.
2. Install the 2 front undershield hooks to the 2 holes in the front undershield support bar.
3. Make sure the front undershield is located correctly.

67.

Install, but do not fully tighten the 2 bolts (D1) as illustrated.

68.

Install, but do not fully tighten the 2 bolts (D1) as illustrated.

69.

Install the 2 fixings (E1) as illustrated.

• Torque: 60 Nm

70.

Tighten the 4 bolts (D1).

• Torque: 60 Nm

71.

Make sure the front undershield (B1) is correctly installed.

READ NEXT: