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LAND ROVER ACCESSORY FITTING INSTRUCTIONS

VEHICLE :
PART NO :
KEYWORD :

LAND ROVER

DEFENDER

RAISED AIR INTAKE

VPLEP0435

FITTING INSTRUCTION

WARNING
  • Accessories which are not correctly installed can be dangerous.
  • Before ordering and installing the accessory, you must read all the instructions. The correct accessory / part must be ordered for you variant of the vehicle.
  • You must follow all instructions. If in doubt, contact your nearest approved retailer.
Kits Required Old Part Number
Raised Air Intake VPLEP0435
Metal A-pillar Bracket (only required if 'Raised Air Intake' kit is supplied with plastic bracket) LR183020

Raised Air Intake - VPLEP0435 (Bill of Materials)

NOTE
  • This kit may contain some variation in the illustrations, but the essential information is always correct.
  • Some kits (VPLEP0435) may contain an old plastic 'A-pillar Bracket' (F). This has been superseded to a metal 'A-pillar Bracket' (LR183020) and this must be ordered and installed instead.
  • If 'Jack Nuts' (E) are damaged during installation, then they must be replaced with new ones (ZKC2228).
  • An additional M6 washer (H) must be locally sourced to aid the installation. Washer must be retained for future use.
Bill Of Materials Replacement Service Part Numbers
(A) Raised Air Intake N/A
(B) Fixing M6x20 LR183020
(C) Rivet Nut LR183020
(D) Fixing M6x25 N/A
(E) Jack Nut ZKC2228
(F) A-pillar Bracket LR183020
(G) Raised Air Intake Cap N/A
(H) M6 Washer (additional part) Locally Sourced

Warnings / Cautions / Notes / Tooling and Equipment

CAUTION
  • Take care to avoid damage to the vehicle paintwork and exterior finishers.
NOTE
  • The raised air intake is always installed to the left side of the vehicle.
  • Normal warranty procedures apply, the locally washer (H) require a justification and breakdown of costs for the consumables. Misc cost code ZZZ123/ZZZ001 must be used and will require the supporting invoice.
Tooling
Oscillating cutting tool
Drill (2, 6 ,8mm)
File or deburring tool
Sharp pick
Scissors
China graph or paint marker
Torque Wrench/Screw Driver (range upto 5Nm)
Trim Removal Tool
Riv Nut/Jack Nut Tool
Ruler (for checking scale if required)
Consumables
M6 Washer (H)
Fitting Instruction
1

Disconnect the 12V battery.

  • Log into TOPIX and enter your 17 character 'Vehicle Identification Number' and navigate to 'Workshop Manual' section '414-00 12V System Disconnect and Connect'.
2
WARNING
  • Heavy component; it requires the aid of another person.
CAUTION
  • Lay the front door on felt-covered supports.
  • Take care not to damage paintwork.

Remove the front door, depending on the side of the vehicle you are working on.

  1. Disconnect the front door wiring harness from the body wiring harness.
  2. Remove fixing to disconnect the front door arm.
  3. Remove x2 fixings and remove the front door.
3

Remove the A-Pillar.

  • Log into TOPIX and enter your 17 character 'Vehicle Identification Number' and navigate to 'Workshop Manual' section '501-11 Glass, Frames and Mechanisms / Windshield Moulding'.
4
NOTE
  • x2 clips will must be retained for the installation later in the instructions.

Use a suitable plastic trim tool to remove the side vent trim. Discard this piece. When pulling the trim away, some clips may remain in place in the fender. Remove these.

5

Clean the illustrated area.

6
WARNING
  • The rivet nut (C) must be correctly formed in the A-pillar. If not installed correctly it can result in failure of the joint.
NOTE
  • Washer (H) is required to aid the installation of the riv nut by providing clearance from the A-pillar retainer highlighted. The washer must be retained for installation of the other side and future use.

Using a rivet nut installation tool, install the rivet nut (C) to the vehicle body, in accordance with the illustrated procedure.

  1. First, install the washer (H) onto the rivet nut installation tool. Next, insert the rivet nut (C) into the tool.
  2. Prior to installing the rivet nut, remove the sticker covering the hole on the vehicle. This will allow access for piercing the hole and subsequent installation of the rivet nut.
  3. Install rivet nut (C) in accordance with the correct location, utilizing the cutout provided in the A-pillar trim. After installing rivet nut (C), the washer (H) can then be removed from the tool.
7
NOTE

Use supplied template and identify if your A-pillar bracket (F) is plastic or metal. Then use the appropriate template to cut out. Then place the template on the inside of the removed A-pillar trim at the top and install with tape. See the above notes for replacement template if damaged.

8

Using a sharp pick indent the x4 drill centres and the dotted lines on the template. Then remove template.

9

Drill x4 pilot holes (2mm) for the corners. Then enlarge the holes with a (6mm) drill.

10

Using an oscillating cutting tool to cut out marked lines.

11

Clean up the edges using a file or deburring tool.

12

Install the modified A-Pillar.

  • Log into TOPIX and enter your 17 character 'Vehicle Identification Number' and navigate to 'Workshop Manual' section '501-11 Glass, Frames and Mechanisms / Windshield Moulding'.
13
CAUTION
  • Take care to avoid damage to the raised air intake (A) when installing the jack nuts (E). Place protective material under the raised air intake during this step.
  • Take care that the jack nuts (E) are not over tightened. Inspect the appearance as illustrated.

Use suitable tooling to install x2 jack nuts (E) to the raised air intake (A) as illustrated. Do not over tighten the nuts.

  1. If Jack nuts are correctly installed. Note the correct recessed position of the thread. The thread must also be concentric to the fixing.
  2. If Jack are nuts damaged. Note the incorrect positioning of the thread which is sitting flush with the face of the fixing. The thread may also appear to one side within the fixing. If damaged new jack nuts can be ordered with part number 'ZKC2228'.
14

Align and position the raised air intake (A) against the vehicle.

  1. Install the arrowed edge.
  2. Inspect the alignment of the full height of the raised air intake against the A-pillar.
  3. Install the arrowed edge. The jack nuts (E) must be aligned with the matching holes.
15
CAUTION
  • Protect the gap between the body and the fender to prevent fixings from dropping into the void.
  • Inspect the alignment of the raised air intake against the vehicle before installing.
NOTE
  • This step requires the aid of another person.

Install, but do not fully tighten the x2 fixings (D) to the x2 jack nuts (E) that are part of the raised air intake.

  • Install the fixings (D) from the inside of the vehicle fender.
16
NOTE
  • If A-Pillar bracket becomes damaged then a new one can be ordered along with its rivet nut and fixing with part number 'LR183020'. Note that an older plastic A-pillar bracket can be replaced with the metal A-pillar bracket 'LR183020'. The cut out in step 10 will not effect this part change.

Install A-pillar bracket (F) into the cutout done in step 10 behind the raised air intake. The hole in the A-pillar bracket (F) must be aligned with the rivet nut (C).

  • The A-pillar bracket must sit directly on to the feature on the A-pillar carrier as illustrated.
17
CAUTION
  • Failure to tighten to the correct torque will result in joint failure.
NOTE
  • The A-pillar trim is hidden to provide extra clarity.

Install fixing (B) through the bracket (F) into the rivet nut (C).

  • Torque: 4Nm
18
WARNING
  • If jack nut (E) is over tightened it will be damaged and result in the raised air intake not being held against the body.
CAUTION
  • This step requires the use of a calibrated torque wrench or screwdriver. Failure to tighten to the correct torque will result in joint failure.

Torque fixings (D). Then paint mark the fixings when the have been correctly tightened.

  • Torque: 3Nm
19

Remove the section of tape at the top of the raised air intake as illustrated.

20

Install cap (G) to the raised air intake and install with clip.

  • Apply pressure to the cap for 15 seconds to install the cap to the adhesive tape on the raised air intake.
21
WARNING
  • Heavy component; it requires the aid of another person.
NOTE
  • Inspect the front door gaps and align if necessary.

Install the front door, depending on the side of the vehicle you are working on.

  1. Offer up the front door to the hinges and Install x2 fixings to install the front door to the vehicle. Torque: 30Nm
  2. Install fixing to connect the front door arm. Torque: 9Nm
  3. Connect the front door wiring harness to the body wiring harness.
  4. Inspect front door alignment. Log into TOPIX and enter your 17 character 'Vehicle Identification Number' and navigate to 'Workshop Manual' section '501-026 Body Repairs - Vehicle Specific Information and Tolerance Checks / Front Door Alignment'.
22

Connect the 12V battery.

  • Log into TOPIX and enter your 17 character 'Vehicle Identification Number' and navigate to 'Workshop Manual' section '414-00 12V System Disconnect and Connect'.
23

Inspect the raised air intake is correctly installed.

  • Inspect that the top of the raised air intake is aligned with the top of the A-pillar trim.
24
NOTE
  • The raised air intake is not a snorkel and is designed not to have a water or air tight installation to the fender. The moulding is designed to install against the fender as illustrated in the photos below.

Inspect the raised air intake is correctly installed.

25

Inspect the raised air intake is correctly installed.

© Land Rover 2016