Defender 90 NAS. Manual — part 83
76
CHASSIS 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
driver’s 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.
76
CHASSIS 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 driver’s 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
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