Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							76CHASSIS AND BODY
18
REPAIR DOOR LOCK - TAIL DOOR
Service repair no - 76.37.16
Remove
1.Remove door trim casing.
See trim casing -
tail door
2.Remove screws, washers and nut retainer plate
securing top of lock to door.
3.Remove nuts, washers and stud retainer plate
securing bottom of lock to door.
4.Withdraw lock assembly.
5.Remove door lock gasket.
6.Clean sealant from retainer plates.
7.Insert key into barrel.
8.Depress lock barrel plunger and withdraw barrel
from lock.
Refit
9.Fit new barrel into lock.
10.Apply sealant to lock retainer plates.
11.Fit lock to door with a new gasket.
12.Secure with retainer plates, screws, washers
and nuts.
13.Close door and check for correct latching with
striker. Adjust striker as necessary.
See
Adjustment, Tail door striker - adjust
14.Fit door trim casing.See trim casing - tail
door 
						

							CHASSIS AND BODY
19
REPAIR SUN ROOF
Service repair no - 76.83.01
Remove
1.Open sun roof fully.
2.Disengage spring lock from operating handle
catch.
3.Holding sun roof at both sides, release hinges
from locating brackets at front of outer frame.4.Remove sun roof.
5.Starting from centre rear, peel headlining finisher
from inner frame.
6.Remove 18 screws securing inner frame to outer
frame and detach inner frame.
7.Lift outer frame from roof.
NOTE: Assistance may be required to
remove the sun roof assembly.
Refit
8.Clean roof area around outer frame seating.
9.Position outer frame on roof.
10.Fit inner frame to headlining and secure to outer
frame with 18 screws but do not fully tighten.
11.Check alignment of inner and outer frames with
roof mounting and headlining, adjust as
necessary, and fully tighten fixing screws to
10
Nm, 7 lbf ft.
12.Starting from centre rear, fit headlining finisher
lip into locating channel of inner frame.
13.Press finisher firmly over inner frame and
continue around complete frame, ensuring
finisher lies flat on headlining.
14.Fit sun roof hinges fully into locating brackets on
outer frame, and lower the glass panel.
15.Engage operating handle catch with spring lock
of outer frame and close sunroof. 
						

							76CHASSIS AND BODY
20
REPAIR INTERIOR MIRROR
Service repair no - 76.10.51
Remove
1.Remove retaining screw securing mirror
adjustment arm to mounting slug.
2.Slide adjustment arm up from mounting slug and
remove mirror.
Refit
3.Slide mirror adjustment arm over mounting slug.
4.Secure mirror with retaining screw.SUN VISORS
Service repair no - 76.10.47
Remove
1.Raise sun visor.
2.Remove 2 screws and collect sun visor.
Refit
3.Position sun visor and secure with 2 screws. 
						

							CHASSIS AND BODY
21
REPAIR FRONT HEADLINING - HARD TOP
Service repair no - 76.64.10
Remove
1.Remove sun roof headlining finisher.
2.Remove sun visors.
See Sun visors
3.Remove interior lamp.See ELECTRICAL,
Repair, Interior lamp
4.Remove 4 retaining screws and detach both A
post trims.
5.Remove caps and unscrew front seat belt fixing
bolts from B/C posts.
6.Carefully prise side trim panel cap fastener from
B/C posts.7.Carefully prise 2 cap fasteners, from each side,
securing headlining to body at door apertures.
8.Carefully prise out 7 cap fasteners securing front
and rear headlinings to roof.
9.From both sides, pull side trim panel inwards
enough to release rear corners of front
headlining.
10.Lower headlining, disconnect interior lamp
harness plug at A post, and remove headlining
from vehicle.
NOTE: Take care not to bend the
headlining on removal and refitting.
11.
Do not carry out further dismantling if
component is removed for access only.
12.Remove interior lamp harness from headlining.
Refit
13.Tape interior lamp harness to headlining.
14.With assistance, raise headlining to roof.
15.Carefully pull side trim panel inwards, on both
sides, and slide headlining behind trim panel.
16.Position front headlining into recess of rear
headlining and secure both to roof mounting
brackets with cap fasteners.
17.Secure both sides of front headlining to body at
door apertures with cap fasteners.18.Fit side cap fasteners at B/C posts.
19.Secure seat belts to B/C posts and tighten bolts
to
32 Nm, 24 lbf ft.Fit caps to bolts.
20.Fit A post trims.
21.Fit interior lamp.
See ELECTRICAL, Repair,
Interior lamp
22.Fit sun visors.See Sun visors
23.Fit sun roof headlining finisher. 
						

							76CHASSIS AND BODY
22
REPAIR REAR HEADLINING - HARD TOP
Service repair no - 76.64.11
Remove
1.Remove rear end trim panel.
See Rear end
trim panel - hard top
2.Remove side trim panels.See Side trim panel
- hard top
3.Remove rear grab handles.See Rear grab
handle - hard top
4.Remove rear end lining.See Rear end lining
hard top
5.Remove rear interior lamp.See ELECTRICAL,
Repair, Interior lamp
6.Remove interior roll-over bar.See Interior
roll-over bar - hard top
7.Carefully prise out 7 trim studs securing rear and
front headlining to roof mounting brackets.
8.Release front corners of headlining from cant
rail, on both sides.
9.Pull headlining forwards sufficiently to clear rear
end lining mounting brackets.
10.Release rear corners of headlining from cant rail,
on both sides.
11.Lower rear headlining from roof and remove
from vehicle.
NOTE: Take care not to bend headlining
on removal and refitting. 
						

							CHASSIS AND BODY
23
REPAIR Refit
12.With assistance, position rear headlining to roof
and locate rear corners in cant rail.
13.Push headlining rearwards and position over
rear end lining mounting brackets.
14.Locate front corners of headlining in cant rail.
15.Position front edge of rear headlining over front
headlining and secure with trim studs.
16.Adjust rear headlining to achieve good fit at all
corners.
17.Fit rear interior lamp.
See ELECTRICAL,
Repair, Interior lamp
18.Fit interior roll-over bar.See Interior roll-over
bar - hard top
19.Fit rear end lining.See Rear end lining - hard
top
20.Fit rear grab handles.See Rear grab handle -
hard top
21.Fit side trim panels.See Side trim panel -
hard top
22.Fit rear end trim panels.See Rear end trim
panel - hard top
BONNET LOCK
Service repair no - 76.16.21
Remove
1.Open bonnet.
2.Mark position of guide plate and lock to bonnet
platform.
3.Remove 8 screws securing grille.
4.Remove grille.
5.Remove 2 bolts securing guide plate and lock.
6.Remove guide plate.
7.Release spring securing lock to bonnet platform.
8.Slacken clamping bolt securing bonnet release
cable.
9.Remove lock.
Refit
10.Fit spring between lock and bonnet platform.
11.Position lock and guide plate to bonnet platform
and nip up bolts.
12.Position guide plate and lock to position marks
and tighten bolts to
10 Nm. 7 lbf/ft.
13.Fit cable to lock and tighten clamping bolt.
14.Check operation of release cable and adjust if
necessary.
15.Fit grille and tighten securing screws.
16.Close bonnet. 
						

							76CHASSIS AND BODY
24
REPAIR BONNET RELEASE CABLE
Service repair no - 76.16.29
Remove
1.Open bonnet.
2.Remove 8 screws securing grille.
3.Remove grille.
4.Slacken clamping bolt securing bonnet release
cable.
5.Remove cable from lock.
6.Release cable from clip on underside of bonnet
platform.
7.Feed cable through valance.
8.Collect cable grommet.
9.Loosen clamping nut securing bonnet release
pull to mounting bracket.
10.Remove bonnet release pull from mounting
bracket.
11.Withdraw cable through bulkhead.
Refit
12.Feed cable through bulkhead and fit bonnet
release pull to mounting bracket. Tighten
clamping nut.
13.Route cable along inner wing.
14.Feed cable through valance.
15.Fit grommet between cable and valance.
16.Fit cable to securing clip on underside of bonnet
platform.
17.Fit cable to lock and tighten clamping bolt.
18.Check operation of release cable and bonnet
lock and adjust if necessary.
19.Fit grille and tighten screws.
20.Close bonnet. 
						

							CHASSIS AND BODY
25
REPAIR LOWER FASCIA PANEL (HEATER DUCT)
ASSEMBLY
Service repair no - 76.46.05
Remove
1.Disconnect battery.
2.Remove steering wheel. If necessary, use puller
LRT-57-014.
3.Remove 7 screws and lift lift top half of nacelle
from steering column switch assembly.
4.Ease bottom half of nacelle from switch
gaiters/grommets and remove.
5.Remove instrument panel.
See INSTRUMENTS,
Repair, Instrument panel
6.Disconnect heater control cable.See HEATING
AND VENTILATION, Repair, Heater control
cable - air distribution
7.Prise out Land Rover decal and remove screw
securing grab handle to crash pad.
8.Remove screw securing grab handle to lower
fascia panel.
9.Lift grab handle to release locating pins from
fascia panel. 
						

							76CHASSIS AND BODY
26
REPAIR
10.Remove 4 screws and remove both demister
vents from crash pad.
11.Remove 3 screws securing crash pad to fascia
bulkhead.
12.Remove crash pad.
13.Remove rear door switch panel.
See
ELECTRICAL, Repair, Switch panel-rear door
services
14.Remove 2 screws, washers and nuts securing
auxiliary switch panel to lower fascia panel and
switch cover.
15.Withdraw switch panel and disconnect harness
leads.
16.Remove 2 screws securing switch cover to
parcel tray.
17.Remove air conditioning fascia duct bezel.
See
AIR CONDITIONING, Repair, Fascia duct
bezel
18.If air conditioning is not fitted, remove 4 screws
and remove both footwell vents from lower fascia
panel.
19.Remove single screw and detach door check
strap cover from LH and RH doors.
20.Remove 3 screws securing wiper motor cover to
fascia bulkhead.
21.Release locating pins from fascia panel, lower
wiper motor cover and disconnect instrument
ilumination switch plug. Retain wiper motor rack
cover.
22.Remove centre console.
See Centre console
23.Prise out 2 large and 5 small cap fasteners
securing trim panel to parcel shelf and fascia
bulkhead.
24.Carefully fold back trim panel to clear fresh air
vent operating levers and remove panel from
parcel shelf.
25.Release demist hose and lift parcel shelf from
lower fascia panel (heater duct). Feed main
harness leads and plugs through aperture in
parcel shelf.
26.Remove parcel shelf.
27.Remove 4 screws securing bottom edge of lower
fascia panel to fascia bulkhead, noting position
of both footwell cover retaining plates. Remove
retaining plates.
28.Unscrew 2 retaining bolts securing top edge of
lower fascia panel to bulkhead.
29.With assistance, release lower fascia panel and
remove from vehicle. 
						

							CHASSIS AND BODY
27
REPAIR Refit
30.Position lower fascia panel to bulkhead and
secure top edge with 2 bolts.
31.Locate RH footwell cover retaining plate under
bottom edge of fascia panel and secure with 3
screws.
32.Repeat operation for LH footwell cover retaining
plate.
33.Fit remaining lower fascia panel fixing screws.
34.Locate parcel shelf. Ensure all rear door services
and auxiliary switch panel harness leads and
plugs are fed through aperture in parcel shelf.
35.Fit demist hoses into heater duct of lower fascia
panel. Ensure flanges of hose grommets are
correctly seated.
36.Fit trim panel and secure with cap fasteners.
37.Fit centre console.
See Centre console
38.Reconnect instrument illumination switch plug
and locate wiper motor cover pins in lower fascia
panel and secure wth 3 screws. Ensure wiper
rack cover is correctly seated.
39.Fit door check strap covers on both sides.
40.Fit air conditioning fascia duct bezel.
See AIR
CONDITIONING, Repair, Fascia duct bezel
41.If air conditioning is not fitted, fit footwell vents to
lower fascia panel.
42.Fit auxiliary switch cover to parcel tray.
43.Connect leads and plugs to auxiliary switches
and clock.
44.Secure switch panel to lower fascia panel and
switch cover.
45.Fit rear door switch panel.
See ELECTRICAL,
Repair, Switch panel-rear door services
46.Fit crash pad to fascia bulkhead.
47.Fit demister vents in crash pad.
48.Fit grab handle to lower fascia panel and secure
to crash pad. Refit Land Rover decal.
49.Connect multi-plugs to rear screen, hazard and
interior lamp switches and fit switch panel to
fascia panel.
50.Fit heater control cable.
See HEATING AND
VENTILATION, Repair, Heater control cable -
air distribution
51.Fit instrument binnacle.See ELECTRICAL,
Repair, Instrument binnacle
52.Fit steering column nacelle.
53.Fit steering wheel.
54.Reconnect battery.FRONT WING [FENDER] ASSEMBLY
Service repair no - 76.11.05
Remove
1.Release exterior roll-over bar from its fitted
position to allow removal of front wing [fender].
See exterior roll-over bar
2.Raise and support front of vehicle on safety
stands.
3.Remove road wheel.
4.Disconnect wiring connectors for parking and
indicator lamps.
5.Disconnect harness multiplug for headlamp.
6.Position wiring clear of wheel arch.
7.Inside wing [fender] rear: Loosen fully 3 bolts
securing wing [fender] bulkhead.
8.Remove 2 bolts securing wheel arch to brackets,
front and rear.
9.From inside engine bay: Remove bolt securing
rear of wing [fender] to bulkhead.
10.Remove 2 bolts securing wing [fender] to
bracket, front bottom.
11.Remove 2 bolts securing wing [fender] to
bracket, front top.
12.Lift wing [fender] assembly and disengage rear
from 3 bolts and remove.
Refit
13.Ensure washers are against heads of bolts with
clearance to insert wing [fender].
14.Position and engage rear of wing [fender] onto
bolts.
15.Fit bolts securing top of wing [fender] to front
bracket, do not tighten.
16.Fit bolts securing bottom of wing [fender] to front
bracket, do not tighten.
17.Fit bolts securing wheel arch to brackets, do not
tighten.
18.Position wiring inside wheel arch.
19.Fit bolt securing top of wing [fender] to bulkhead.
20.Align wing [fender] to A post and tighten bolts
inside wing [fender] and at top.
25 Nm, 18 lbf ft.
21.Align front of wing [fender] and tighten bolts at
front.
25 Nm, 18 lbf ft.
22.Tighten bolts inside wheel arch.25 Nm, 18 lbf ft.
23.Connect wiring.
24.Fit road wheel and lower vehicle, tighten nuts to
130 Nm, 95 lbf ft.
25.Fit exterior roll-over bar.See exterior roll-over
bar