Land Rover Defender V8i Workshop Supplement Rover Manual

							76CHASSIS AND BODY
8
REPAIR INTERIOR ROLL-OVER BAR
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
3.Remove side trim panels.See side trim panel
4.Remove centre console.See centre console
5.Remove 4 bolts securing centre section of
roll-over bar and seat belt stalks to floor.
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 wheel arches.
12.Remove roll-over bar from vehicle.
NOTE: Assistance may be required to
remove roll-over bar. 
						

							CHASSIS AND BODY
9
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 wheel arches. 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.Secure seat belt stalks and roll-over bar floor
mounting brackets to chassis. Tighten bolts to
32
Nm (24 lbf ft.
20.Fully tighten roll-over bar centre section retaining
bolts to
45 Nm (33 lbf.ft).
21.Fit centre console.See Centre console; Refit
22.Fit side trim panel.See Side trim panel; Refit
23.Fit rear end trim panels.See Rear end trim
panel; Refit
24.Fit rear seat squabs.See Rear seat squabs;
Refit
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
3.Remove rear speaker.See ELECTRICAL,
Repair, rear speaker
4.Peel back carpet and remove 2 screws securing
speaker panel to wheel arch.
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; Refit
11.Fit rear end trim panel.See rear end trim
panel; Refit 
						

							76CHASSIS AND BODY
10
REPAIR REAR TOW BAR
Service repair no - 76.11.41
Remove
1.Remove 4 bolts securing anti-roll bar to rear
undertray.
2.Remove 6 bolts securing rear undertray to
chassis.
3.Remove rear undertray.4.Remove bolt, washer and nut from both sides,
securing tow bar lower mounting brackets and
towing eyes to chassis.
5.Remove 4 bolts and spring washers securing
tow bar centre mounting bracket to chassis.
6.Remove both bolts securing 2 tow bar locating
tubes in rear chassis cross member.
7.Remove 2 bolts securing tow bar top mounting
brackets to chassis.
8.With assistance, withdraw tow bar assembly
from chassis.
Refit
9.With assistance, lift tow bar assembly and locate
both tubes in chassis crossmember.
10.Secure top tow bar mounting brackets to chassis
but do not fully tighten fixings.
11.Secure tow bar locating tubes to rear of chassis
and tighten bolts to
25 Nm (18 lbf.ft).
12.Secure tow bar centre mounting bracket to
underside of chassis and tighten bolts to
25 Nm
(18 lbf.ft).
13.Position towing eyes to lower mounting brackets
and secure to chassis and tighten bolts to
25 Nm
(18 lbf.ft).
14.Fully tighten tow bar top mounting bracket bolts
to
25 Nm (18 lbf.ft).
15.Fit rear undertray and secure to chassis with
bolts.
16.Fit bolts securing rear anti-roll bar and tighten to
30 Nm (22 lbf.ft). 
						

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

							76CHASSIS AND BODY
12
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
wings.
5.Remove grille panel.
Refit
6.Position grille panel and fit bolts to wing, 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; Refit 
						

							CHASSIS AND BODY
13
REPAIR BONNET
Service repair no - 76.16.01.99
Remove
1.Remove split pin from bonnet stay 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 stay from pivot, fold stay up into
the 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 stay to
pivot.
13.Fit anti-rattle and plain washers to pivot. Secure
with split pin.
14.Release stay and close bonnet to check
alignment and operation. 
						

							82 - AIR CONDITIONING
CONTENTS
Page
FAULT DIAGNOSIS
REFRIGERATION SYSTEM FAULTS 1.................................................................
ADJUSTMENT
GENERAL PRECAUTIONS 1.................................................................................
REMEDIAL ACTIONS 1..........................................................................................
SERVICING PRECAUTIONS 2...............................................................................
REFRIGERANT RECOVERY, RECYCLING, RECHARGING 3.............................
LEAK TEST SYSTEM 4..........................................................................................
AIR CONDITIONING SYSTEM - PERFORMANCE TEST 5...................................
SYSTEM TEST 6....................................................................................................
REPAIR
COMPRESSOR 1...................................................................................................
CONDENSER 2......................................................................................................
RECEIVER DRIER 3...............................................................................................
TRINARY PRESSURE SWITCH 4..........................................................................
CONTROL SWITCHES 4........................................................................................
RESISTOR UNIT 5..................................................................................................
FASCIA DUCT BEZEL 5.........................................................................................
EXPANSION VALVE 7............................................................................................
BLOWER MOTOR ASSEMBLY 7...........................................................................
EVAPORATOR 8....................................................................................................
WIRING HARNESS - SUPPLEMENTARY 10.........................................................
SPECIFICATIONS, TORQUE
TORQUE VALUES 1............................................................................................... 
						

							AIR CONDITIONING
1
FAULT DIAGNOSIS REFRIGERATION SYSTEM FAULTS
For any refrigeration system to function properly all
components must be in good working order. The unit
cooling cycle and the relationship between air
discharge temperature and ambient temperature and
the pressures at the compressor can help to
determine proper operation of the system.
The length of any cooling cycle is determined by such
factors as ambient temperature and humidity,
thermostat setting, compressor speed and air leakage
into the cooled area, etc. With these factors constant,
any sudden increase in the length of the cooling cycle
would be indicative of abnormal operation of the air
conditioner.
The low and high side pressures at the compressor
will vary with changing ambient temperature, humidity,
in-car temperature and altitude.
The following items should be checked before
operating the system:
1.Compressor drive belt tension.
2.Compressor magnetic clutch operation.
3.Condenser fan operation.
4.Condenser fins, dirt will cause poor cooling and
higher operating temperatures.System check
The following conditions should be checked after
operating the system for several minutes:
1.All high pressure lines and components should
be hot to the touch.
2.All low pressure lines should be cool to the
touch.
3.Inlet and outlet temperatures at the receiver/drier
should be at the same temperature (warm). Any
very noticeable temperature difference indicates
a blocked receiver/drier.
4.Heavy frost on the inlet to the expansion valve
may indicate a defective valve or moisture in the
system.
5.Evaporation air temperature will vary with
ambient temperature and humidity. As humidity
increases the outlet temperature will be higher.