Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							CHASSIS AND BODY
3
DESCRIPTION AND OPERATION CHASSIS ALIGNMENT DIMENSIONS
A Front Datum
B Chassis Datum
C Front axle centre line
D Rear axle centre line
1.239,0 - 236,5 mm 9.41 - 9.31 in
2.82,0 - 79,5 mm 3.23 - 3.13 in
3.633 mm 24.921 in
4.2420,6 - 2418,6 mm 94.51 - 95.22 in
5.2306,4 - 2305,4 mm 90.80 - 90.76 in
6.981,2 - 978,7 mm 38.63 - 38.53 in
7.182,7 mm 7.19 in
8.41,5 - 37,0 mm 1.63 - 1.46 in
9.252 - 250 mm 9.92 - 9.84 in
10.110 mm 4.33 in
11.2360mm - 92.91 in - Wheelbase
12.636 - 634 mm 25.04 - 24.96 in
13.488 - 483 mm 19.21 - 19.01
14.488 - 483 mm 19.21 - 19.01 in
15.3431,1 - 3426,1 mm 135.08 - 134.89 in
16.588,3 - 586,3 mm 23.16 - 23.08 in
17.2313,8 - 2311,8 mm 91.09 - 91.06 in
18.590,5 mm 23.25 in
19.295,25 mm 11.62 in20.519,60 - 517,00 mm 20.46 - 20.35 in
21.259,80 - 258,50 mm 10.23 - 10.18 in
22.1242,6 - 1240,6 mm 48.92 - 48.84 in
23.642,5 - 639,5 mm 25.30 - 25.18 in
24.750,9 mm 29.56 in
25.439,5 - 436,5 mm 17.30 - 17.18 in
26.136,5 mm 5.37 in
27.299,5 - 295,5 mm 11.79 - 1163 in
28.103 - 100 mm 4.06 - 3.94 in
29.131,5 - 126,5 mm 5.18 - 4.98 in
30.705,5 - 704,5 mm 27.76 - 27.74 in
31.705,5 - 704,5 mm 27.76 - 27.74 in
32.42,2 - 40,2 mm 1.66 - 1.58 in
33.491 - 486 mm 19.33 - 19.13 in
34.594,2 - 593,4 mm 23.39 - 23.36 in
35.283,0 - 282,2 mm 11.14 - 11.11 in
36.32,25 - 31,25 mm 1.27 - 1.23 in
37.397 - 395 mm 15.63 - 15.55 in 
						

							76CHASSIS AND BODY
4
DESCRIPTION AND OPERATION
Chassis frame alignment
With the vehicle assembled a check for chassis
squareness can be made as follows:
1.Place the vehicle on a level floor.
2.Mark measuring points at approximately the
locations shown, ensure that the marks are
exactly opposite on each side of the chassis
frame.
3.Hold a plumb line against each of the measuring
points in turn and mark the floor directly beneath
the plumb-bob.4.Move the vehicle and measure diagonally
between the marks made on the floor, if the
chassis is square the diagonals between the
related measuring points should agree within
9,50 mm.
5.Chassis frame dimensional checks can be
made, with the vehicle upper structure removed,
referring to the applicable illustration and
associated key. 
						

							CHASSIS AND BODY
1
ADJUSTMENT DOOR LOCK STRIKER - ADJUST
Service repair no - 76.37.23
Adjust
1.Loosen Torx bolts securing striker to B post.
2.Adjust alignment of striker vertically and
horizontally, lightly tighten bolts.
3.Close door, check for correct latching with door
lock and for centring on striker.
4.Add or remove packing shims as necessary.
Fully tighten bolts.
5.Carry out further adjustment as necessary. If full
adjustment cannot be achieved carry out
following:
6.Remove striker and nut plate.
7.Elongate striker bolt holes in B post to increase
movement in direction required.
8.Refit striker and adjust as necessary.TAIL DOOR STRIKER - ADJUST
Service repair no - 76.37.25
Adjust
1.Loosen striker securing screws.
2.Adjust striker vertically and horizontally, lightly
tighten screws.
3.Close door and check for correct latching with
door lock.
4.Carry out further adjustment as necessary. If full
adjustment cannot be achieved carry out
following:
5.Remove striker and nut plate.
6.Elongate holes in body panel in direction
required.
7.Refit striker and adjust as necessary. 
						

							CHASSIS AND BODY
1
REPAIR FRONT DOOR - HARD TOP
Front door lock mechanism - RH shown 
						

							76CHASSIS AND BODY
2
REPAIR TRIM CASING - FRONT DOOR
Service repair no - 76.34.01
Remove
1.Prise open finisher caps, remove 2 screws, and
detach door pull.
2.Remove single screw behind remote control
lever.
3.Prise off remote control lever bezel.
4.Prise off door locking button bezel.
5.Prise out window regulator handle centre
finisher, remove retaining screw, and withdraw
handle and bezel.
6.Using a screwdriver to release trim fasteners,
carefully ease trim casing from door. 
						

							CHASSIS AND BODY
3
REPAIR Refit
7.Remove any trim fasteners held in door panel.
Refit or insert new clips to trim casing.
8.Ensure that anti-vibration pads are in position
and offer-up trim casing to door. Line-up
fasteners with holes in door and firmly push trim
into position.
9.Fit bezels to locking button and remote control
lever.
10.Fit single screw behind remote control lever.
11.Fit door pull and secure with 2 screws and
finisher caps.
12.Fit window regulator handle and retain with
single screw and finisher.MOUNTING PANEL - FRONT DOOR
Service repair no - 76.11.28
Remove
1.Remove door trim casing
See Trim casing -
front door
and plastic sheet.
2.Remove 4 screws securing window regulator to
mounting panel.
3.Remove 5 screws securing mounting panel to
door frame. 
						

							76CHASSIS AND BODY
4
REPAIR
4.Release remote control lever rod from latch
mechanism and from plastic clip in mounting
panel.
5.Slide window regulator arm from mounting panel
channel and remove panel with remote control
lever and rod.
Refit
6.Engage window regulator arm in mounting panel
channel.
7.Connect remote control rod to latch mechanism
and secure with clip.
8.Fit mounting panel and retain with 5 screws.
9.Secure window regulator to mounting panel with
4 screws.
10.Raise and lower window to check for free
movement.
11.Fit plastic sheet and door trim casing.
See Trim
casing - front door
SILL LOCKING BUTTON - FRONT DOOR
Service repair no - 76.37.29
Remove
1.Remove door trim casing.
See Trim casing -
front door
2.Peel back plastic sheet to expose mechanism.
3.Release spring clip and disconnect operating rod
from latch mechanism.
4.Remove 2 screws and withdraw locking button
assembly.
Refit
5.Secure locking button assembly to door with 2
screws.
6.Connect operating rod to latch mechanism and
secure with spring clip.
7.Re-seal plastic sheet and fit door trim casing.
See Trim casing - front door 
						

							CHASSIS AND BODY
5
REPAIR WINDOW REGULATOR - FRONT DOOR
Service repair no - 76.31.45
Remove
1.Remove door trim casing.
See Trim casing -
front door
2.Remove plastic sheet.
3.Temporarily fit handle, position window half open
and support with a length of timber.
4.Remove 2 lower screws securing mounting
panel to door and slacken 3 upper screws.
5.Remove 4 screws retaining window regulator to
mounting panel and slide operating arms from
channels attached to glass and mounting panel
and remove regulator.
Refit
6.Insert regulator operating arms into channels.
7.Fit and tighten mounting panel lower screws and
tighten upper screws.
8.Align holes in regulator with holes in mounting
panel and secure with 4 screws.
9.Temporarily fit regulator handle and check that
glass can be raised and lowered without tight
spots.
10.Secure plastic sheet.
11.Fit door trim casing.
See Trim casing - front
door
REMOTE CONTROL LEVER - FRONT DOOR
Service repair no - 76.37.31
Remove
1.Remove door trim.
See Trim casing - front
door
2.Peel back sufficient of plastic sheet to gain
access to remote lever.
3.Release spring clip and disconnect control rod
from latch mechanism.
4.Release control rod from plastic clip in mounting
panel.
5.Remove 2 screws securing remote control lever
to mounting panel and withdraw lever and
control rod. 
						

							76CHASSIS AND BODY
6
REPAIR Refit
6.Feed control rod into position and loosely secure
lever to mounting panel with 2 screws.
7.Connect control rod to latch mechanism and
secure with spring clip.
8.Tighten control lever retaining screws.
9.Secure control rod to plastic clip in mounting
panel.
10.Secure plastic sheet with adhesive.
11.Fit door trim casing.
See Trim casing - front
door
EXTERIOR HANDLE - FRONT DOOR
Service repair no - 76.58.01
Remove
1.Remove door trim casing.
See Trim casing -
front door
2.Remove mounting panel.See Mounting panel
- front door
and support glass with timber.
3.Disconnect operating rod from handle
mechanism.
4.Disconnect rod from locking barrel lever.
5.Remove 2 screws and withdraw handle
assembly. 
						

							CHASSIS AND BODY
7
REPAIR Refit
6.Fit handle to door ensuring that two bezels are in
position - flat faces towards door, and secure
with 2 screws.
7.Connect rod to handle operating lever and
secure with spring clip.
8.Connect rod to locking barrel lever and retain
with spring clip.
9.Fit mounting panel
See Mounting panel - front
door
10.Fit door trim casing.See Trim casing - front
door