Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							76CHASSIS AND BODY
28
REPAIR TRIM CASING - FRONT DOOR SOFT TOP
Service repair no - 76.34.01
Remove
1.Prise open 2 finishers and remove 2 screws
securing door pull.
2.Remove 13 screws securing door trim casing.
3.Release trim casing from door, disconnect wires
from speaker and withdraw casing from door
handle.
Refit
4.Ensure screw inserts are in door panel or use
new inserts. Ensure that anti-vibration pads are
in position on trim casing.
5.Position trim casing to door, connect speaker
wiring and engage door handle, align fixings in
door and secure with screws.
6.Fit door pull, secure with screws and insert
finishers.FRONT DOOR LOCK - SOFT TOP
Service repair no - 76.37.12
Remove
1.Remove door casing.
See Trim casing - front
door soft top
2.Remove 2 screws, washers and nut retainer
securing top of lock to door.
3.Remove 2 nuts, washers and screw retainer
securing bottom of lock to door.
4.Withdraw lock complete from door panel.
5.Remove door lock gasket.
6.Clean sealant from retainer plates.
7.Insert key into barrel, depress lock barrel plunger
and withdraw lock barrel.
Refit
8.Fit new barrel into lock.
9.Apply sealant to lock retainer plates.
10.Fit lock to door with a NEW gasket.
11.Secure with retainer plates, screws, washers
and nuts.
12.Close door and check for correct latching with
striker.
13.Adjust striker as necessary.
See Adjustment,
Door lock striker - adjust
14.Refit door casing.See Trim casing - front
door soft top 
						

							CHASSIS AND BODY
29
REPAIR TAIL DOOR LOCK - SOFT TOP
Service repair no - 76.37.16
Remove
1.Open tail door.
2.Remove 2 screws, washers and nut retainer
securing top of lock to door.
3.Remove 2 nuts, washers and screw retainer
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, depress lock barrel plunger
and withdraw barrel from lock.Refit
8.Fit new barrel into lock.
9.Apply sealant to lock retainer plates.
10.Fit lock to door with a NEW gasket.
11.Secure with retainer plates, screws, washers
and nuts.
12.Close door and check for correct latching with
striker.
13.Adjust striker as necessary.
See Adjustment,
tail door striker - adjust
PRIVATE LOCK - TAIL DOOR
Service repair no - 76.37.42
Remove
1.Remove tail door lock.
See Door lock - tail
door
2.Insert key in barrel.
3.Depress lock barrel plunger (seeST1979M).
4.Withdraw barrel from lock.
Refit
5.Reverse removal procedure.
6.Refit tail door lock.
See Door lock - tail door 
						

							76CHASSIS AND BODY
30
REPAIR EXTERIOR ROLL-OVER BAR
Service repair no - 76.11.39
Remove
1.Remove torx bolt, from both sides, securing top
of roll-over bar to roof mounted bar.
2.With assistance to support roll-over bar at
windscreen, remove 4 torx bolts, from both
sides, securing roll-over bar to fender mounting.3.Remove two torx bolts, from both sides, securing
top bar to roof mounting.
4.Slide top bars rearwards to disengage from main
roll-over bar assembly.
5.Lift main roll-over bar assembly from vehicle.
6.If necessary, remove 2 torx bolts and nuts, from
both sides, and detach lower cross bar from
main roll-over bar.
Refit
7.Locate lower cross bar into main roll-over bar
mounting brackets and secure with torx bolts
and nuts to
25 Nm, 18 lbf ft.
8.Ensure rubber gaskets are fitted correctly to
roll-over bar mounting brackets.
9.With assistance, lift roll-over bar assembly and
position on fenders.10.Slide top bars into main roll-over bar, position on
roof mounting and secure with torx bolts to
25
Nm, 18 lbf ft.
11.Secure roll-over bar to both fender mountings
with torx bolts. Tighten to
25 Nm, 18 lbf ft.
12.Secure top bars to main roll-over bar and tighten
fixing bolts to
25 Nm, 18 lbf ft. 
						

							CHASSIS AND BODY
31
REPAIR INTERIOR ROLL-OVER BAR - HARD TOP
Service repair no - 76.11.40
Remove
1.Remove rear seat squabs.
See rear seat
squab
2.Remove rear end trim panels.See rear end
trim panel - hard top
3.Remove side trim panels.See side trim panel
- hard top
4.Remove centre console.See Centre console
5.Remove 4 bolts securing centre section of
roll-over bar and seat belt stalks to floor. On
drivers side, disconnect harness plug connector
of audible warning circuit at belt stalk.
6.Remove 2 torx bolts and nuts from both sides
and detach centre section of roll-over bar
assembly.7.Remove torx bolt, from both sides, securing
roll-over bar to body side mounting brackets.
8.Remove 3 bolts and washers, from both sides,
securing lower roll-over bar brackets to front of
wheelarch.
9.Remove 2 torx bolts and washers, from both
sides, securing roll-over bar upper mountings to
roof fixing brackets and carefully lower complete
assembly to floor.
10.Unscrew retaining bolts, from both sides, and
remove front seat belt inertia reels and rear seat
belts from roll-over bar mounting.
11.Supporting from both sides, raise and tilt
roll-over bar rearwards to clear wheelarches.
12.Remove roll-over bar from vehicle.
NOTE: Assistance may be required to
remove roll-over bar. 
						

							76CHASSIS AND BODY
32
REPAIR Refit
13.Supporting from both sides, position roll-over
bar, engage struts in rear corners and front of
side panels. Align on floor.
14.Secure front seat belt inertia reels and rear seat
belts to roll-over bar mountings. Tighten bolts to
32 Nm, 24 lbf ft.
15.Raise roll-over bar assembly and secure to roof
mounting brackets. Tighten bolts to
45 Nm, 33
lbf ft.
16.Secure roll-over bar to wheelarches. Tighten
bolts to
45 Nm, 33 lbf ft.
17.Secure roll-over bar to body side mounting
brackets, tightening bolts to
45 Nm, 33 lbf ft.
18.Secure centre section to main roll-over bar, but
do not fully tighten fixing bolts at this stage.
19.Reconnect drivers seat belt audible warning
harness plug.
20.Secure seat belt stalks and roll-over bar floor
mounting brackets to chassis. Tighten bolts to
32
Nm, 24 lbf ft.
21.Fully tighten roll-over bar centre section retaining
bolts to
45 Nm, 33 lbf ft.
22.Fit centre console.See Centre console
23.Fit side trim panel.See Side trim panel
REAR SPEAKER PANEL
Service repair no - 76.13.11
Remove
1.Raise seat cushion and fit stowage strap.
2.Remove rear end trim panel.
See rear end trim
panel - hard top
3.Remove rear speaker.See ELECTRICAL,
Repair, rear speaker
4.Peel back carpet and remove 2 screws securing
speaker panel to wheelarch.
5.Prise top edge of panel down to release from
body channel.
6.Remove speaker panel.
Refit
7.Position speaker panel on wheel arch.
8.Press top edge of panel down firmly and locate
under body channel.
9.Secure speaker panel to wheel arch with screws
and reposition carpet.
10.Fit rear speaker.
See ELECTRICAL, Repair,
rear radio speaker
11.Fit rear end trim panel.See rear end trim
panel - hard top 
						

							CHASSIS AND BODY
33
REPAIR WINDSCREEN GLASS
Service repair no - 76.81.01
Remove
1.Remove windscreen wiper arms.
See WIPERS
AND WASHERS, Repair, Wiper arm
2.Remove rear view mirror.See Interior rear
view mirror
3.Remove 2 screws from each side and release A
post finishers.
4.Cover windscreen demist vents with tape to
prevent ingress of glass particles.
5.From the outside: Free lip of the sealing rubber
from sealant along top of frame and down each
side.
6.With an assistant supporting the glass from
outside and starting at a top corner, press
windscreen glass outwards and release sealing
rubber from flange.
7.Remove sealing rubber from glass.
WARNING: If glass has splintered, protect
the eyes and use protective gloves.
8.If windscreen has broken, ensure that all
particles of glass are removed. Use a vacuum
cleaner to remove glass from fascia, carpets and
seats.
9.Check frame for distortion and damage to flange,
dress and true flange as necessary. Apply
primer to any bare metal.
10.Remove particles of glass and examine sealing
rubber for cuts and damage, renew as nessary.Refit
11.Lay glass on felt covered supports,DO NOT
stand on edge.
CAUTION: Any chipping of glass edge may
develop into cracks.
12.Apply a soap solution to glazing channel of
sealing rubber.
13.Align sealing rubber to glass and fit by working
around glass and easing sealing lips over glass
edge.
14.Insert a cord around the flange channel of
sealing rubber so that ends cross over at the
bottom.
15.Apply a soap solution around sealing rubber to
aid fitment.
16.Place glass assembly against frame ensuring
sealing rubber has equal overlap all round with
draw cord over bottom of flange.
17.Assistant from outside, press sealing rubber
firmly against flange and use cord to pull lip of
seal over flange.
18.Carefully work around sealing rubber and
equalize seal to glass and flange.
19.Apply a bead of windscreen sealant under
outside sealing lip, along each side and across
the top.
20.Fit rear view mirror.
See Interior rear view
mirror
21.Fit A post finishers.
22.Remove tape from demist vents.
23.Fit windscreen wiper arms.
See WIPERS AND
WASHERS, Repair, Wiper arm 
						

							76CHASSIS AND BODY
34
REPAIR REAR TOW BAR
Service repair no - 76.11.41
Remove
1.Remove bolt, washer and nut from both sides,
securing tow bar lower mounting brackets and
towing [fender] eyes to chassis.2.Remove 4 bolts and spring washers securing
tow bar centre mounting bracket to chassis.
3.Remove both bolts securing 2 tow bar locating
tubes in rear chassis cross member.
4.Remove 2 bolts securing tow bar top mounting
brackets to chassis.
5.With assistance, withdraw tow bar assembly
from chassis.
Refit
6.With assistance, lift tow bar assembly and locate
both tubes in chassis crossmember.
7.Secure top tow bar mounting brackets to chassis
but do not fully tighten fixings.
8.Secure tow bar locating tubes to rear of chassis
and tighten bolts to
25 Nm, 18 lbf ft.
9.Secure tow bar centre mounting bracket to
underside of chassis and tighten bolts to
25 Nm,
18 lbf ft.
10.Position towing [fender] eyes to lower mounting
brackets and secure to chassis and tighten bolts
to
25 Nm, 18 lbf ft.
11.Fully tighten tow bar top mounting bracket bolts
to
25 Nm, 18 lbf ft. 
						

							CHASSIS AND BODY
35
REPAIR BONNET
Service repair no - 76.16.01/99
Remove
1.Remove split [cotter] pin from bonnet prop lower
pivot.
2.Remove washer and anti-rattle washer from
pivot.
3.Position suitable chock to support bonnet in a
position to gain access to hinge nuts.
4.Release bonnet prop from pivot, fold prop up into
bonnet and rest bonnet onto chock.
5.Mark outline of hinge on bonnet.
6.Remove 6 nuts and screws securing bonnet to
hinges.
7.With assistance, remove bonnet.
Refit
8.With assistance, position bonnet to hinges.
9.With assistance, fit screws through hinges and
bonnet and fit washers and nuts to screws.
10.Align hinges to bonnet markings.
11.Tighten hinge retaining screws.
12.Raise bonnet from chock and connect prop to
pivot.
13.Fit anti-rattle and plain washers to pivot and
secure with split [cotter] pin.
14.Release prop and close bonnet to check
alignment and operation. 
						

							76CHASSIS AND BODY
36
REPAIR CENTRE CONSOLE
Service repair no - 76.25.01
Remove
1.Open cubby box lid.
2.Remove in-car entertainment unit - if fitted.
3.Remove 6 screws securing cubby box to
console.
4.Remove cubby box.
5.Release rear edge of selector housing surround.
6.Remove surround.
7.Release hi-low gear lever gaiter from console.
8.Remove hi-low gear lever knob and gaiter
assembly.
9.Remove tray from console.
10.Remove screw securing front edge of console.
11.Remove 3 screws securing rear of console.
12.Remove console.Refit
13.Fit and align console.
14.Fit and tighten screws securing console.
15.Fit tray to console.
16.Fit hi-low gear lever knob and gaiter assembly.
17.Secure hi-low gear lever gaiter to console.
18.Fit gear selector housing surround and secure.
19.Fit cubby box to console and secure with
screws.
20.Fit in-car entertainment unit - if fitted.
21.Close cubby box lid. 
						

							CHASSIS AND BODY
37
REPAIR RADIATOR GRILLE
Service repair no - 76.55.03
Remove
1.Remove 8 screws securing grille to front panel.
2.Remove radiator grille
Refit
3.Position radiator grille to front panel.
4.Secure grille with screws.GRILLE PANEL
Service repair no - 76.55.06
Remove
1.Remove radiator grille.
See radiator grille
2.Disconnect multiplug from condenser fan
fly-lead.
3.Loosen bolts securing top panel and grille panel
to fenders.
4.Remove bolts securing securing grille panel to
fenders.
5.Remove grille panel.
Refit
6.Position grille panel and fit bolts to fender, finger
tight.
7.Fit plastic nuts to lower fixing, each side
8.Fit screws to top panel.
9.Align grille panel and tighten all fixings.
10.Fit radiator grille.
See radiator grille