Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							76CHASSIS AND BODY
8
REPAIR LATCH ASSEMBLY - FRONT DOOR
Service repair no - 76.37.12
Remove
1.Remove mounting panel.
See Mounting panel
- front door
and support glass with timber.
2.Disconnect control rod from handle operating
lever.
3.Disconnect control rod from locking lever on
handle.
4.Disconnect locking button control rod from latch
mechanism.
5.Remove 2 screws and remove handle assembly
from door.
6.Remove 2 self-tapping screws retaining lower
end of window glass runner.
7.Remove 3 screws securing latch assembly to
door.
8.Whilst taking care not to damage runner, ease
runner away from latch and manoeuvre latch
asembly from door.
Refit
9.Carefully ease window runner away, sufficiently
to enable latch to be located into position.
10.Secure latch to door with 3 screws.
11.Secure window runner with 2 screws ensuring
that packing strip is in position and that screw
heads are below bottom of runner to prevent
damage to glass.
12.Fit handle with 2 screws, ensuring that bezels
are in position.
13.Connect control rod to handle operating lever
and secure with spring clip.
14.Connect control rod to locking lever and retain
with spring clip.
15.Connect locking button control rod to latch lever
and secure with spring clip.
16.Fit mounting panel.
See Mounting panel -
front door 
						

							CHASSIS AND BODY
9
REPAIR DOOR GLASS - FRONT DOOR
Service repair no - 76.31.01
Remove
1.Remove mounting panel.See Mounting panel
- front door
2.Remove window regulator.See Window
regulator - front door
3.Push glass up to top of its travel and support
with a suitable length of timber.
4.Remove 2 self tapping screws securing window
glass runner on latch side of door and single
screw from hinge side.
5.Taking care not to damage paint, prise exterior
waist weather strip from door.
6.Remove timber support and lower glass to
bottom of door.
7.Ease runner from glass at hinge side of door, lift
glass over bottom edge of door and withdraw. 
						

							76CHASSIS AND BODY
10
REPAIR
Refit
8.Insert glass into runners at an angle as
illustrated.
9.Whilst lifting glass, position it squarely in
runners, raise to top of travel and insert timber
support.
10.Secure hinge side runner with single screw
ensuring that packing strip is in position.
11.Locate packing strip and secure opposite runner
with 2 screws. Ensure that all 3 screw heads are
well below bottom of runners to prevent damage
to glass.
12.Locate regulator in window lift channels.
13.Fit mounting panel
See Mounting panel - front
door
LOCKING BARREL - FRONT DOOR
Service repair no - 76.37.39
Remove
1.Remove door trim
See Trim casing - front
door
and plastic sheet.
2.Remove mounting panel
See Mounting panel
- front door
3.Raise and support glass to gain access to latch
mechanism.
4.Release spring clip and disconnect rod from lock
operating lever.
5.Remove single screw and withdraw lock lever
assembly.
6.Withdraw lock barrel from exterior door handle
complete with locking sleeve. 
						

							CHASSIS AND BODY
11
REPAIR
7.To remove barrel from plastic retaining sleeve,
depess spring loaded button and withdraw
sleeve.
Refit
NOTE: If a new barrel is being fitted, check
that number on barrel coincides with
number on accompanying key.
8.Push plastic retaining sleeve over barrel until
spring loaded peg locks it into position.
9.Fit barrel and plastic sleeve assembly to locking
sleeve and insert into exterior handle reversing
instruction 6.
10.Assemble lock lever components as illustrated
and from inside of door panel, fit them to barrel
assembly with single screw.
11.Connect operating rod to lock lever and secure
with spring clip, reversing instruction 4.
12.Fit mounting panel.
See Mounting panel -
front door
REAR SEAT CUSHION
Service repair no - 78.10.18/99
Remove
1.Release seat cushion stowage strap.
2.Remove 4 bolts and spring washers and lift seat
cushion from pivot brackets.
3.Remove 4 bolts, plain washers, spring washers
and nuts. Detach both pivot brackets from wheel
arch.
Refit
4.Secure pivot brackets to wheel arch and tighten
bolts to
10 Nm, 7 lbf ft.
5.Position seat cushion in pivot brackets and
secure with 4 bolts and spring washers.
6.Fit stowage strap. 
						

							76CHASSIS AND BODY
12
REPAIR REAR SEAT SQUAB
Service repair no - 78.10.58/99
Remove
1.Release seat cushion stowage strap and lower
seat cushion.
2.Loosen 2 bolts securing seat squab brackets to
body side.
3.Remove 2 bolts, plain washers, spring washers
and nuts securing seat squab to wheel arch.
4.Lift and release brackets from retaining bolts and
remove seat squab.
Refit
5.Lower seat squab brackets over retaining bolts,
tighten bolts to
10 Nm, 7 lbf ft.
6.Secure seat squab to wheel arch, tighten bolts to
10 Nm, 7 lbf ft.
7.Raise seat cushion and fit stowage strap. 
						

							CHASSIS AND BODY
13
REPAIR REAR SEAT BELTS
Service repair no - 76.73.18
Remove
1.Release belt straps from buckles on both seats.
2.Raise both seat cushions and secure with
stowage straps.
3.Unscrew bolt and remove bracket and inner seat
belt straps.4.Unscrew bolt and remove rear seat buckle strap
from wheel arch.
5.Unscrew bolt and remove front seat buckle strap
from interior roll-over bar mounting.
Refit
6.Reverse removal procedure, ensuring seat belt
fixing bolts are tightened to
32 Nm, 24 lbf ft). 
						

							76CHASSIS AND BODY
14
REPAIR FRONT SEAT BELTS
Service repair no - 76.73.13
Remove
1.Remove cap and unscrew seat belt guide
bracket fixing bolt from B/C post.
2.Remove 3 bolts and plain washers securing seat
belt mounting bracket to body on outside of seat
base.3.Prise seat belt retaining clip from side of seat
mounting and remove trim studs.
4.Unscrew bolt and remove seat belt inertia reel
from roll-over bar mounting bracket.
5.Remove seat belt and inertia reel assembly.
6.Unscrew bolt and washer and remove seat belt
buckle stalk from roll-over mounting bracket.
7.On the drivers side, disconnect harness plug
connector of audible warning circuit at buckle
stalk.
Refit
8.Reconnect harness plug of audible warning
circuit.
9.Position stalk on roll-over bar mounting bracket
and tighten fixing bolt to
32 Nm, 24 lbf ft.
10.Secure seat belt inertia reel to roll-over bar
mounting and tighten bolt to
32 Nm, 24 lbf ft.
11.Secure seat belt backet to floor on outside of
seat base and tighten bolts to
23 Nm, 17 lbf ft).
12.Fit seat belt retaining clip to side of seat base
and secure with trim studs.
13.Extend belt from inertia reel, secure slide bracket
to B/C post and tighten bolt to
32 Nm, 24 lbf ft.
14.Refit fixing bolt cap. 
						

							CHASSIS AND BODY
15
REPAIR SIDE TRIM PANEL - HARD TOP
Service repair no - 76.13.70
Remove
1.Remove rear seat squabs.
See Rear seat
squab
2.Remove rear end trim panel.See Rear end
trim panel - hard top
3.Prise cap from front seat belt upper guide
retaining bolt.4.Unscrew retaining bolt and remove seat belt
from B/C post.
5.Carefully prise 2 trim studs from B/Cpost.
6.Remove 4 bolts securing side trim panel and
forward seat support to body side.
7.Release top edge of side trim panel by striking
upwards with the hand to disengage 3 spring
clips.
8.Carefully pull trim panel rearwards to clear
interior roll-over bar.
9.Remove side trim panel from vehicle.
Refit
10.Fit new spring clips to the 3 brackets on top
edge of side trim panel.
11.Carefully pull trim panel behind interior roll-over
bar.
12.Align trim panel, ensuring it is correctly
positioned around side window.
13.Locate trim panel spring clips on inner cant rail
and press firmly down to secure top edge of trim
panel.14.Align bosses of trim panel and forward seat
support bracket with body side fixing holes and
secure with bolts and washers.Do notfully
tighten at this stage.
15.Fit trim stud to secure bottom edge of trim panel
to B/C post.
16.Secure seat belt guide to B/C post, tighten bolt
to
32 Nm, 24 lbf/ftand fit cap.
17.Fit rear end trim panel.
See Rear end trim
panel - hard top
18.Fit rear seat squab.See Rear seat squab 
						

							76CHASSIS AND BODY
16
REPAIR REAR END TRIM PANEL - HARD TOP
Service repair no - 76.13.71
Remove
1.Pull edge of rear end trim panel firmly to release
the two spring retaining clips from vertical rail at
door aperture.
2.Remove rear end trim panel.
Refit
3.Fit new spring clips to the two brackets on side
of trim panel.
4.Position outboard edge of trim panel in corner to
abut side trim panel and locate spring clips on
vertical rail.
5.Press edge of trim panel firmly to secure in
position.REAR GRAB HANDLE - HARD TOP
Service repair no - 76.58.35
Remove
1.Carefully prise top and bottom edges of finisher
caps from grab handle and then hinge outwards
to gain access to fixing screws.
2.Remove 4 fixing screws and detach grab handle
from rear end trim panel.
Refit
3.Position grab handle on rear end trim panel and
secure with 4 fixing screws.
4.Press finisher caps over screws. 
						

							CHASSIS AND BODY
17
REPAIR REAR END LINING - HARD TOP
Service repair no - 76.64.12
Remove
1.Remove rear end trim panel.
See Rear end
trim panel - hard top
2.Remove rear grab handles.See Rear grab
handle - hard top
3.Carefully prise out 6 trim studs securing rear end
lining to mounting brackets.
4.Remove rear end lining.
Refit
5.Position rear end lining on mounting brackets
and secure with 6 trim studs.
6.Fit rear grab handles.
See rear grab handle -
hard top
7.Fit rear end trim panel.See rear end trim -
hard top
TRIM CASING - TAIL DOOR
Service repair no - 76.34.09
Remove
1.Unscrew 2 bolts and remove grab handle from
rear door.
2.Remove 2 screws and detach wiper motor cover.
3.Remove 7 screws securing trim casing to door.
4.Remove 2 screws and lift wiper motor harness
cover from harness support bracket.
5.Carefully release 8 clips securing trim casing to
door.
6.Remove trim casing and collect door lock cover.
Refit
7.Position door lock cover, fit trim casing and
secure with clips.
8.Fit harness cover and secure with two screws.
9.Secure door panel with retaining screws.
10.Position wiper motor cover and secure with 2
screws.
11.Position grab handle and secure with 2 bolts.