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LAND ROVER ACCESSORY FITTING INSTRUCTIONS

VEHICLE :
PART NO :
KEYWORD :

LAND ROVER

DEFENDER

EXTERIOR SIDE-MOUNTED GEAR CARRIER

VPLEP0437 / VPLEP0508 / VPLEP0531 / VPLEP0542 / VPLEP0511 / VPLEP0512 / VPLLE0017 / VPLLE0011 / VPLLE0012

FITTING INSTRUCTION

WARNING
  • Accessories which are not correctly installed can be dangerous. Read the instructions carefully prior to ordering and installation to make sure this accessory is applicable to your variant of vehicle. Comply with instructions at all times. If in doubt, contact your nearest approved retailer.
Accessories Part Number Superseded By
Exterior Side-Mounted Gear Carrier - Silver (Defender 90/110) VPLEP0437 or VPLEP0531 or VPLEP0542
Exterior Side-Mounted Gear Carrier - Black (Defender 90/110) VPLEP0511 VPLLE0011
Exterior Side-Mounted Gear Carrier - Silver (Defender 130) VPLEP0508
Exterior Side-Mounted Gear Carrier - Black (Defender 130) VPLEP0512 VPLLE0012
Exterior Side-Mounted Gear Carrier - Sedona Red (Defender 130) VPLLE0017

Exterior Side-Mounted Gear Carrier (Bill of Materials)

Warnings / Cautions / Notes

WARNING
  • Make sure to wear suitable personal protective equipment when drilling or cutting parts.
  • Maximum carrying capacity of the exterior side-mounted gear carrier is 17kg.
CAUTION
  • The vehicle must be equipped with roof rails if the exterior side-mounted gear carrier is to be installed.
  • If the expedition roof rack is also going to be installed to the vehicle then the exterior side-mounted gear carrier must be installed first and then the expedition roof rack installed afterwards.
  • The vehicle manufacturer recommends the use of specialised satin paint products when cleaning the exterior side-mounted gear carrier. Any other cleaning or paint protection product may have an adverse effect on the paint finish.
  • Never polish accessories that have a satin matte paint finish. Polishing causes the finish to shine and may reduce the matte effect.
  • Do not use an automated car wash. Using unapproved cleaning equipment can cause damage to the exterior side-mounted gear carrier.
  • Do not affix stickers, films, magnetic plates, or similar items to the exterior side-mounted gear carrier. Any such objects may damage the paint finish.
  • Additional care is required when cleaning accessories with a satin matte paint finish. It is recommended to wash accessories by hand, using a soft sponge, and making sure not to apply high pressure to the paint surface. Avoid washing accessories in direct sunlight. Remove any of the following substances immediately, where possible: insect remains, bird droppings, fingerprints, tree resin, oils, grease and fuels, wax and tar spots.
NOTE
  • The keys, item (N) must be kept in a safe place. The keys will be required to operate the exterior side-mounted gear carrier.
  • This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
  • The exterior side-mounted gear carrier can only be installed to the right side of the vehicle.
  • The locking system used on this accessory is compatible with the Thule key system. To order replacement keys, refer to your local Thule retailer/website and quote the number stamped into the face of the lock cylinder, for example - N123. For this accessory, the key model number begins with 1500000***, so for example, the model number for key number N123 would be 1500000123.
  • Any spare parts must be handed over to the customer during the demonstration handover.
  • Inside Dimensions Length: 608.575mm x Height: 361.585mm x Width: 131.997mm.
  • Volume capacity 28L.
Fitting Instruction
1

Identifying the side trim

  • Locate the side trim for your specific vehicle variant.
2
NOTE
  • Illustration shows Defender 110. Process is same for Defender 90/130.

Cleaning.

  • Clean the surface of the side trim and the surrounding area.
3
NOTE
  • Illustration shows Defender 110. Process is same for Defender 90/130.

Remove side trim.

  1. Using a plastic trim tool, carefully pry away the side trim (as illustrated) while the door is open to access the end of the side trim.
  2. Make sure all clips are removed from the body undamaged if left behind and refitted to the side trim.
4
CAUTION
  • Make sure the painted surface is protected when modifying the trim.

Modify side trim for Defender 90 vehicles 'ONLY'.

  1. Measure and mark x2 positions on the side trim using the measurements as illustrated. Offer up the side trim to make sure they are inline with the thread holes on the vehicle before proceeding.
  2. Use template (M) and attach over the top of the trim and slide into position over the marked holes. Drill x2 pilot holes and then remove the template (templates must be attached with the arrows facing downward).
  3. Turn over the side trim and use an appropriate tool to cut away the x2 arrowed metal strips. (Removing the metal strips will make drilling easier in the next step).
  4. Drill holes at the x2 marked positions. Use a 20 mm step drill bit. Then proceed to step 7.
5
CAUTION
  • Make sure the painted surface is protected when modifying the trim.

Modify side trim for Defender 110 vehicles 'ONLY'.

  1. Measure and mark x2 positions on the side trim using the measurements as illustrated. Offer up the side trim to make sure they are inline with the thread holes on the vehicle before proceeding.
  2. Use template (M) and attach over the top of the trim and slide into position over the marked holes. Drill x2 pilot holes and then remove the template (templates must be attached with the arrows facing downward).
  3. Turn over the side trim and use an appropriate tool to cut away the x2 arrowed metal strips. (Removing the metal strips will make drilling easier in the next step).
  4. Drill holes at the x2 marked positions. Use a 20 mm step drill bit. Then proceed to step 7.
6
CAUTION
  • Make sure the painted surface is protected when modifying the trim.

Modify side trim for Defender 130 vehicles 'ONLY'

  1. Measure and mark x2 positions on the side trim using the measurements as illustrated. Offer up the side trim to make sure they are inline with the thread holes on the vehicle before proceeding.
  2. Use template (M) and attach over the top of the trim and slide into position over the marked holes. Drill x2 pilot holes and then remove the template (templates must be attached with the arrows facing downward).
  3. Turn over the side trim and use an appropriate tool to cut away the x2 arrowed metal strips. (Removing the metal strips will make drilling easier in the next step).
  4. Drill holes at the x2 marked positions. Use a 20 mm step drill bit. Then proceed to step 7.
7
CAUTION
  • Do not cut or remove the rubber seal located behind the U-cut on the side trim.
NOTE
  • Make sure to tape surrounding area of drilled hole prior to opening out the top area to minimize risk of scratching the end trim.

Enlarging drill holes.

  • Using suitable tooling to enlarge the drilled holes at the top to create a 'U' shaped hole (as illustrated).
8
CAUTION
  • Do not remove the water sealing patch from the middle vehicle body fixing nut.
NOTE
  • Defender 90 vehicles 'ONLY'.

Removing sealing patches.

  • Remove x2 water sealing patches from the two locations (as illustrated) where they cover the vehicle body fixing nuts, making way for component installation.
9
CAUTION
  • Do not remove the water sealing patch from the middle vehicle body fixing nut.
NOTE
  • Defender 110 / 130 vehicles 'ONLY'.

Removing sealing patches.

  • Remove x2 water sealing patches from the two locations (as illustrated) where they cover the vehicle body fixing nuts, making way for component installation.
10
NOTE
  • Illustration shows Defender 130. Process is same for Defender 90/110.
  • Spacer (E) must be counter held when installing fixing (D).

Install fixings (D) and spacers (E).

  • Install x2 fixings (D) and x2 spacers (E) as illustrated, making sure fixings (D) is install into the vehicle body fixing nuts. Torque: 38Nm
11
NOTE
  • Illustration shows Defender 110. Process is same for Defender 90/130.

Install bracket fixing points (F).

  1. Locate the bracket fixing points into the large cutout in the roof rail slots.
  2. Check the bracket is fully inserted as illustrated.
  3. Slide the bracket fixing points along the roof rail and align them with the bottom fixings (D).
12
CAUTION
  • Make sure the side trim seal is lipped under the glass.
  • Make sure the clips are located in the body holes.

Install the modified side trim.

  • Clip the side trim back into position. Make sure the holes in the side trim do not make contact with the bottom fixings (D).
13
NOTE
  • There are x2 grommets (I). One is not used and kept as a spare.

Open the gear carrier (A) and install grommet (I).

  1. Unlock the exterior side-mounted gear carrier using the keys (N).
  2. Hold the bottom edge of the gear carrier lid and lift upwards until the lid is nearly horizontal. The locking arm will reach the maximum extent and an audible click is heard and the lid can be released and will stay open.
  3. From the inside of the side-mounted gear carrier install grommet (I) in location shown.
14

Install brackets (B).

  1. Install the brackets as illustrated, identifying them by the labels 'F' (Forward) and 'R' (Rear).
  2. Open the side mounted gear carrier and install x4 fixings (C) through it and into the brackets. Torque: 11Nm
15
CAUTION
  • Make sure the keys (N) are removed from the gear carrier before closing. There is a risk the keys will become locked inside the gear carrier.
NOTE
  • The gear carrier can be locked without using the keys. If the lid is closed when the keys are removed then the gear carrier will lock. The keys will be required to unlock it again.

Close the gear carrier (A) lid.

  1. Pull downward on the lid to disengage the locking arm.
  2. The lid will swing downward to the vertical position.
  3. Press on the lock barrel. An audible click is heard when the lid has locked.
16
CAUTION
  • Care must be taken to avoid damaging the surrounding paintwork.
  • The aid of another technician is required to complete this step.
NOTE
  • Illustration shows Defender 110. Process is same for Defender 90/130.

Positioning the gear carrier (A).

  • Place the gear carrier into position, as shown in the illustration.
17
CAUTION
  • Care must be taken to avoid damaging the surrounding paintwork.
  • The aid of another technician is required to complete this step.
NOTE
  • Illustration shows Defender 110. Process is same for Defender 90/130.

Install the gear carrier (A) to the vehicle.

  • Install, but do not fully tighten top fixings (G), (H) and (J) as illustrated.
18
NOTE
  • Illustration shows Defender 110. Process is same for Defender 90/130.

Install the gear carrier (A) to the vehicle.

  1. Position the gear carrier over the fixings (D).
  2. Install, but do not fully tighten bottom fixings (K) and (L).
19

Fasten the gear carrier (A) to the vehicle.

  1. When you are happy that the gear carrier is sitting correctly, tighten top fixings (G) Torque: 11Nm
  2. Open gear carrier lid for easier access and tighten bottom fixings (K) Torque: 11Nm.
20

Install caps (O).

  1. Install the x2 caps.
  2. Then close and lock lid.
21

Then Inspect that the gear carrier is installed securely and locked.

© Land Rover 2016