LAND ROVER

DEFENDER

FRONT EXPEDITION PROTECTION SYSTEM

VPLLE0016 / VPLEP0386 / VPLEB0437 / VPLEB0435 - VPLEB0436 - VPLEB0434 / VPLEB0441 / LR138717 / VPLEP0436 - VPLLE0034

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.

Kits Required	Part Number	Superseded by
Front Expedition Protection System	VPLEP0386	VPLLE0016
Camera Mounting Kit (Optional)	VPLEB0437
China Market Number Plate Plinth	VPLEB0434
EU Market Number Plate Plinth	VPLEB0435
NAS / Japan Market Number Plate Plinth	VPLEB0436
Defender-X 'ONLY' Front Bumper Protector	VPLEB0441
Parking Aid Sensors (Optional)	LR138717
Front Undershield - Standard	VPLEP0436
Front Undershield - Black	VPLLE0034

Front Expedition Protection System 1 of 2 (Bill of Materials)

Front Expedition Protection System 2 of 2 (Bill of Materials)

Front Undershield (Bill of Materials) - VPLEP0436 or VPLLE0034

Warnings / Cautions and Notes

CAUTION

For Defender-X only vehicles the prepared front bumper protector (VPLEB0441) must be ordered. Front bumper protector (VPLEB0441) comes ordered in a primer condition and needs to painted in (Narvik Black).

NOTE

Paid subscription to TOPIX required to view workshop manual links.

Remove radiator grille.

Log into TOPIX and enter your 17 character 'Vehicle Identification Number' and navigate to 'Workshop Manual' section '501-08 Radiator Grille'.

NOTE

This step requires the aid of another technician.
Discard the front bumper lower cover as this will not get installed again.
Discard the x2 outside lower panels, removed in step 8 of the front bumper workshop manual, as these will not get installed again.

Remove the front bumper.

Log into TOPIX and enter your 17 character 'Vehicle Identification Number' and navigate to 'Workshop Manual' section '501-19 Front Bumper'.

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 ordered.

Remove and retain x2 parking aid sensors (S1) from the front bumper.

Disconnect the parking aid sensor harness from the parking aid sensor.
Remove the parking aid sensor from the front bumper.

CAUTION

This step must be completed to make sure there is sufficient harness length to allow the camera to be installed to the A-frame cover.

Remove the arrowed tape and the arrowed clip securing the camera harness to the front wiring harness.

Disconnect the camera harness from the camera.

NOTE

Retain the license plate and the license plate fixings.

Remove the license plate and the license plate fixings.

NOTE

The existing vehicle license plate plinth cannot be installed to the 'A' frame protection bar. A new license plate plinth must be ordered that can be installed to the 'A' frame protection bar. The correct license plate plinth for the vehicle market must be ordered.

Remove the license plate plinth if installed. Discard the license plate plinth.

CAUTION

Take extra care not to damage the clips.

NOTE

Repeat this step for the other side.

Remove the fog lamp finisher.

Release x7 clips.
Remove the fog lamp finisher from front bumper.

Remove x6 fixings.

CAUTION

Take extra care not to damage the clips.

NOTE

Make sure all fixings are retained.

Remove the front bumper protector.

Remove x2 fixings.
Release x20 clips.
Remove the front bumper protector.

Remove the camera housing and the front proximity camera from the front bumper grille part.

Remove x3 fixings.

Remove the front proximity camera from the camera housing.

Remove the front proximity camera from the camera housing. Retain the front proximity camera (S2).
Discard the camera housing.

NOTE

Make sure all fixings and parking aid sensors are retained.

Remove the front bumper lower corner covers from both sides of the front bumper.

Disconnect the parking aid sensors. The quantity of parking aid sensors will vary depending on the vehicle specification.
Remove parking aid sensors as required to allow removal of the front bumper lower corner covers.

NOTE

The cut guide line is found on the reverse side of the part.

Identify the cut guide lines on the front bumper lower corner covers.

WARNING

Make sure to wear suitable personal protective equipment.

CAUTION

Take extra care to make sure the cut follows the cut guide lines exactly. There is a risk of irreversible damage to the part.

Use suitable tooling to cut the illustrated sections from the front bumper lower corner covers. Discard the removed sections.

Use the cut guide lines on the front bumper lower corner covers.

WARNING

Make sure to wear suitable personal protective equipment.

CAUTION

Take extra care to make sure the holes are drilled at the correct location as illustrated.

NOTE

The markings are found on the reverse side of the part.

Drill 4 holes in the lower corner of the front bumper carrier as illustrated. Repeat step for the other side of the front bumper.

Use the arrowed markings on the front bumper lower corner to make sure the holes are drilled at the correct locations.
10 mm drill bit

CAUTION

Move aside any harnesses that are positioned near to the cut guide lines.

NOTE

The cut guide line is found on the reverse side of the part.

Identify the cut guide lines on the lower corners of the front bumper carrier.

WARNING

Make sure to wear suitable personal protective equipment.

CAUTION

Take extra care to make sure the cut follows the cut guide lines exactly. There is a risk of irreversible damage to the part.
Take care to avoid cutting the harness that is located in this area of the bumper carrier.

Use suitable tooling to cut the illustrated part from the front bumper carrier. Repeat step for the other side of the front bumper carrier.

Use the cut guide lines on the front bumper carrier.

CAUTION

For Defender-X only vehicles, the prepared front bumper protector (VPLEB0441) must be ordered. The front bumper protector comes already pre-cut.

NOTE

Front bumper protector (VPLEB0441) comes ordered in a primer condition and needs to painted in (Narvik Black).
Make sure to remove and retain the grille part of the front bumper protector removed from the vehicle.

For Defender-X vehicles only, do not complete steps 21 to 26. Continue from step 27.

Install the front grille taken from the removed front bumper protector, and install it to the Defender-X front bumper protector (VPLEB0441).
Discard the front bumper protector that was removed from the vehicle. The front bumper protector (VPLEB0441) will be installed instead.

NOTE

Take care to mark the hole position accurately.

Mark a point at the centre of the front bumper protector.

Make sure the mark is centred between the 2 parking aid sensor holes.

WARNING

Make sure to wear suitable personal protective equipment.

Drill a hole at the marked position.

22 mm drill bit

CAUTION

There are multiple cut guide lines on the front bumper protector. There is a risk of irreversible damage to the part if the correct cut guide lines are not followed.

NOTE

The cut guide lines are found on the reverse side of the part.

Identify the correct cut guide lines on the front bumper protector.

WARNING

Make sure to wear suitable personal protective equipment.

CAUTION

There are multiple cut guide lines on the surface of the part. Make sure the correct cut guide lines are followed as illustrated.

Use suitable tooling to cut the illustrated sections from the front bumper protector. Discard the removed sections.

Use the cut guide lines on the front bumper protector.

CAUTION

There are multiple cut guide lines on the front bumper protector. There is a risk of irreversible damage to the part if the correct cut guide lines are not followed.

NOTE

The cut guide lines are found on the reverse side of the part.

Identify the correct cut guide lines on the front bumper protector for the parking aid sensor holes.

WARNING

Make sure to wear suitable personal protective equipment.

CAUTION

There are multiple cut guide lines on the surface of the part. Make sure the correct cut guide lines are followed as illustrated.

Use suitable tooling to drill the illustrated parking aid sensor holes in the front bumper protector. Discard the removed sections.

Use the cut guide lines on the front bumper protector.
The holes can be drilled using a 32 mm to 40 mm circular saw.

CAUTION

Extra care must be taken to avoid cutting the arrowed feature.

NOTE

The cut guide lines are found on the reverse side of the part.

Identify the correct cut guide lines on the radiator grille.

WARNING

Make sure to wear suitable personal protective equipment.

CAUTION

There are multiple cut guide lines on the surface of the part. Make sure the correct cut guide lines are followed as illustrated.

Use suitable tooling to cut the illustrated sections from the radiator grille. Discard the removed sections.

Use the cut guide lines on the radiator grille.

NOTE

Make sure to retain all fixings (S6). Some of the fixings will be used again when the front section of the front wheel arch liner is installed again.

Remove the front section of the front wheel arch liner on both sides of the vehicle.

Log into TOPIX and enter your 17 character 'Vehicle Identification Number' and navigate to 'Workshop Manual' section '501-02 Front Wheel Arch Liner'.

Identify the cut guide lines on the front wheel arch liner.

WARNING

Make sure to wear suitable personal protective equipment.

CAUTION

Take extra care to make sure the cut follows the cut guide lines exactly. There is a risk of irreversible damage to the part.

Use suitable tooling to cut the section of the front wheel arch liner on both sides of the vehicle as illustrated. Discard the removed sections.

Use the cut guide lines on the wheel arch liner.

Remove the x2 brake ducts.

Remove x4 brake duct fixings (S3) and retain.
Remove the x2 brake ducts and retain.

CAUTION

On P6 vehicle variants there is a cooling pipe that must be removed from the cooling module protector.

Release and aside the cooling pipe from the cooling module protector as illustrated.

Release the cooling pipe from the x2 arrowed clips and aside the cooling pipe.
Remove x2 clips (S4) and retain.

CAUTION

Carefully move aside the air conditioning pipes on both sides of the cooling module protector to allow access.

Remove the cooling module protector as illustrated.

Remove and retain x2 cooling module protector M12 bolts (S5).
Remove and discard x2 cooling module protector bolts as illustrated. Move aside the air conditioning pipes to allow access.
Remove and discard the cooling module protector.

NOTE

Complete install step 2 to 5 before tightening (x8) armature bolts.

Loosen x8 armature bolts to assist the installation of the front undershield support bar (A1).

NOTE

This step requires the aid of another technician.

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

Align the front undershield support bar with the vehicle.
Align the ends of the front undershield support bar with the brackets as illustrated.
Make sure the holes for the bolts (S5) align with the holes in the subframe. Adjust the armature position to achieve correct hole alignment.
Install, but do not fully tighten x2 fixings (S5) to secure the front undershield support bar to the vehicle.

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.

Check the alignment of the front undershield support bar with the bracket as illustrated.
Install, but do not fully tighten x2 fixings (C1) to secure the front undershield support bar to the bracket.
Make sure the air conditioning pipes on both sides of the front undershield support bar are installed in the correct location.

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.

Install x2 clips (S4) to the front undershield support bar.
Install the cooling pipe to the x2 arrowed clips and position the cooling pipe as required.

Tighten fixings (S5) and (C1).

Torque: 60Nm

Tighten x8 armature bolts.

Torque: 55Nm

Install the x2 brake ducts to the front undershield support bar using x4 fixings (S3).

NOTE

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

Install x8 rivet nuts (U) to the lower corners of the front bumper carrier. Then follow the process below or use a rivet nut fastening tool.

Install fixing (V) to each of the rivet nuts (U).
Tighten each fixing (V) to collapse the rivet nut it is installed into.
Remove all fixings (V) and retain.

NOTE

Install, but do not fully tighten x4 fixings (D).

Install the x2 lower brackets (L) to the front bumper carrier using x4 fixings (D), x8 washers (S) and x4 nuts (T).

Position the A-frame carrier (A) onto the front bumper carrier and make sure the x2 brackets (L) are positioned correctly.

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.
If required adjust the position of the brackets (L).

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

Tighten x4 fixings (D) that secure the x2 lower brackets (L) to the front bumper carrier.

Torque: 12Nm

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

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

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.

CAUTION

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.

NOTE

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 x8 front bumper clips on both sides.
Install x6 lower clips to the front bumper.
Install and tighten the upper x5 fixings to the front bumper. Torque: 3.2Nm

NOTE

Repeat this step for the other side.

Install the front bumper finisher.

Install x7 clips.

NOTE

Install, but do not fully tighten the x4 bolts (D).

Install the x2 upper brackets (E) to the front of the vehicle using the x4 fixings (D), x8 washers (S) and x4 nuts (T).

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

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

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

Tighten x4 fixings (D) that secure the 2 upper brackets (E) to the front bumper.

Torque: 12Nm

If required install the upper grille to the radiator grille.

Install x10 clips.
Install the upper grille.

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

Install x14 clips.
Install the radiator grille.
Install x4 clips.

CAUTION

For Defender-X only vehicles the prepared front bumper protector (VPLEB0441) must be installed.

NOTE

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.

Feed the 2 centre parking aid sensor harnesses through the illustrated holes in the front bumper protector.
Install x20 front bumper protector clips.
Install and tighten x8 fixings. Torque: 4Nm

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 x7 clips.

NOTE

This step requires the aid of another technician.
Install but do not fully tighten x8 fixings (D).

Install the A-frame carrier (A) using x8 fixings (D) and the washers (S) to check the alignment.

Make sure the A-frame carrier location pin is aligned with the hole in the centre of the front bumper protector.
Align the A-frame carrier to the x4 brackets (E) and (L).
Install but do not fully tighten x8 fixings (D).

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.

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

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

Install x14 rib locks (K) to the A-frame carrier (A).

Install x6 clips (H) to the A-frame carrier (A).

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 centre of the front bumper bracket.

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

NOTE

This step requires the aid of another technician.

Install the A-frame carrier (A) using x8 fixings (D) and the washers (S).

Make sure the A-frame carrier location pin is aligned with the hole in the centre of the front bumper bracket.
Align the A-frame carrier to the x4 brackets (E) and (L).
Install but do not fully tighten x8 fixings (D).

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.

Tighten x8 fixings (D).

Torque: 12Nm

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.

NOTE

Complete step only if installing a China market license plate plinth (VPLEB0434).
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

NOTE

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

NOTE

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 (VPLEB0435).

2 mm drill bit

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).

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

NOTE

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).

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

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

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).

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

Install x10 fixings (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: 8Nm

Install x7 remaining rib locks (K) to the A-frame centre trim (C).

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 centre trim (C).

Align and locate the camera bracket (J) to the A-frame centre trim (C).
Make sure the camera bracket is correctly installed as illustrated.
Install x2 fixings (I).

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

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

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.

CAUTION

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

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

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

CAUTION

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.

NOTE

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 x2 fixings (N) and the 2 holes drilled in install steps 46 to 49.

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

NOTE

Complete step only if required.

Install the remaining x6 fixings (N) to the license plate plinth.

China market.
NAS or Japan market.
EU market.

Install the license plate to the license plate plinth.

Install the hood latch panel finisher.
Install x6 clips.

WARNING

Make sure to wear suitable personal protective equipment.

CAUTION

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.

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

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.

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

Align the expedition corner cover to the lower corner cover.
Apply pressure to the expedition corner cover to secure the cover to the promoter.
Install the x2 arrowed clips, that are part of the expedition corner cover, over the front bumper carrier as illustrated.

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

Install, but do not fully tighten x4 fixings (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.

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 x2 retained fixings (S6).

Log into TOPIX and enter your 17 character 'Vehicle Identification Number' and navigate to 'Workshop Manual' section '501-02 Front Wheel Arch Liner'.

Install, but do not fully tighten x3 fixings (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.

Remove the x4 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.

Tighten x4 fixings (V).

Torque: 2Nm

Tighten x4 fixings (W) and the retained fixing (S6).

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

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

Remove x4 fixings. Keep x2 and discard the other x2. All fixings are the same.

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

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

Install, but do not fully tighten x2 fixings from step 66.

Install, but do not fully tighten x2 fixings (D1).

Install x2 fixings (E1).

Torque: 60Nm

Tighten x4 fixings.

Torque: 60Nm

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