Range Rover Manual Body Chassis

Range Rover Manual Body Chassis
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BODY REPAIRS, GENERAL INFORMATION
Welding
The Range Rover body consists of a steel frame to
which alloy outer panels are attached. The cowl
panel, front fenders, side door outer panels, body
side outer panels and roof are made from a special
light magnesium-aluminium alloy.
CAUTION: The battery ground lead MUST be
The manufacture of body panels from aluminium
has two distinct advantages, the first of which is a
much better resistance to corrosion, the second
being a decrease in the gross vehicle weight.
Aluminium panels can be effectively repaired using
the ‘Argon Arc ’ process of welding, because the
afore mentioned is a specialist operation it is
necessary that only a skilled operator or specialist
body shop undertake such repairs.
.:
CHASSIS AND BODY
Under certain conditions it may’ not be practical to
repair an exterior damaged panel, if this is the case,
then panels can be easily removed and replaced
with new ones (refer to the appropriate part of the
Body section for panel removal and refit).
disconnected before commencing welding. IF
WELDING IS TO BE CARRIED OUT ON THE REAR
RIGHT HAND FENDER, THE FENDER MUST BE
REMOVED, AS A FUEL EXPANSION TANK IS
LOCATED BETWEEN THE FENDER AND INNER
BODY SIDE.
1. Clean off all grease and paint, dry thoroughly
and then clean the edges to be welded, and
an area at least half an inch on either side of
the weld, with a stiff wire scratch brush or
wire wool. Cleanliness is essential. Also clean
the welding rod or strip with steel wool.
2. It is strongly recommended that a few welds
are made on scrap metal before the actual
repair is undertaken if the operator is not
already experienced in welding aluminium and
its alloys.
3. Use only 5 per cent magnesium aluminium
welding rod (5 Mg/A).
Welding tears and patching
Panel beating
.T..
1. Aluminium alloy panels can be beaten out
after accidental damage in the same way as
sheet
steel. However, under protracted
hammering the material will harden, and then
it must be annealed to prevent the possibility
of cracking. This is quite easily done by the
followed by slow
application
of heat,
air-cooling, but as the melting point is low,
heat must be applied slowly and carefully.
CAUTION: Before applying heat to any panel
ensure that the panel is clean and free from
underseal and that the area to be worked on is
well clear of any combustible materials. Ensure
that all necessary precautions are taken against
fire. IF HEAT IS TO BE APPLIED TO THE REAR
RIGHT HAND FENDER, THE FENDER MUST FIRST
BE REMOVED AS A FUEL EXPANSION TANK IS
LOCATED BETWEEN THE FENDER AND INNER
BODY SIDE.
1. If a tear extends to the edge of a panel, start
the weld from the end away from the edge
and also at this point drill a small hole to
prevent the crack spreading, then work
towards the edge.
2. When welding a long tear, or making a long
welded joint, tack the edges to be welded at
intervals of from 2 in to 4 in (50 to 100mm)
with spots. This is done by melting the metal
at the starting end and fusing into it a small
amount of the filler rod, repeating the process
at the suggested intervals. After this, weld
continuously along the joint from right to left,
increasing the speed of the weld as the
material heats up.
3. When patching, cut the patch to the correct
shape for the hole to be filled, but of such
sizes as to leave a gap of l/32 in (0.80mm)
between it and the panel, and then weld as
described above. Never apply an ‘overlay’
patch.
1
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76
1987 RANGE
ROVER
‘CHASSIS AND BODY
Spot welding
PAINTWORK
is mainly used in the
. 1. spot welding
manufacture of the Range-Rover inner steel
body frame and exterior magnesium-aluminium
alloy panels, and is a process which can be
carried out satisfactorily by the use of the
proper apparatus in a specialist body shop.
Aluminium and its alloys are very good
conductors of heat and electricity, and thus it
is most important to maintain the right
conditions for successful spot welding. The
correct current density must be maintained,
and so must the ‘dwell’ of the electrodes.
Special spot welding machines have been
developed, but they are expensive, and
though the actual work can be carried out by
comparatively unskilled labour, supervision and
machine maintenance must be in the hands of
properly qualified persons.
General Information
Riveting
1. Where both sides of the metal are accessible
and it is possible to use an anvil or ‘dolly’
solid aluminium rivets may be used, with a
suitable punch or ‘pop’ to ensure clean
rounded head on the work. For riveting blind
holes, ‘pop-rivets’ must be used. These are
inserted and closed by special ‘Lazy-Tong’
‘pop-rivet’ pliers.
2
Before undertaking any paintwork process on the
exterior body of Range Rover, firstly ascertain which
is the best method of repair either by panel repair
or replacement.
The initial preparation of a panel is very important
to ensure that when finished it is of a standard that
meets and matches existing bodywork. Panels must
be thoroughly degreased with Berger Preclean
802.0516 or a suitable equivalent, any unsound
paint to be stripped using Berger Double strength
Meltic 3 0 1 . 8 0 5 1 . A l w a y s r e f e r t o t h e p a i n t
manufacturers instructions.
Paintwork processes should be performed by a
specialist bodyshop where paint spraying can be
undertaken in a controlled environment whereby
temperatures are kept constant and the atmosphere
dust free.
The flow chart on the following page gives a guide
to preparing and painting a panel. Wherever
possible refer to the Berger Vehicle Refinishes
Product Data and Application Sheets for further
information.
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j
RANGE
ROVER
1987
CHASSIS AND BODY
SUBSTRATE
ALUMINIUM PANELS
I
I
PANEL REPAIR
I
REPLACEMENT PANEL
‘REPARATION
Vet for using P60 Grade paper or dry
and using P240 grit discs.
Wet flat using P60 Grade paper or dry
sand using P240 grit discs. Care must
be taken to avord cutting through to
bare aluminium.
lODY FILLING
f filling is required, thoroughly
lbrade bare alumrnium area to be
illed and apply Standox Polyester
Jopper 430-5029.
If filling is required, fill small
indentations with Standox Polyster
stopper 430-5029.
iTCHlNG
This process is not required if the
itch the bare aluminium and filler
original electrocoat primer is in
with auto-speed self etch
lrimer 414-1171, mixed 1:l with actrvator
-1;;;zzondition.
301-7995. Apply one coat and
allow to dry for approximately 20
ninutes.
Zecoat within 1 hour.
1
‘RIMING
To obtain maximum adhesion and excellent build, apply Standox
2K 4:l full primer 405-0381. Coats of 30-40 microns can be wet
flatted with P60 grade paper after 45 minutes at 20°C.
COLOUR COATING
Apply either Standox 2K Standocryl or Standox Metallic Basislack
to the colour required. Hardeners and thrnners will var)
depending upon system employed, conditions available,
temperature and size of vehicle etc. Refer to paint manufacturers
Technical Information Sheet for correct selection.
REVISED: MARCH 90
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RANGE
1987-90 ROVER
CHASSIS AND BODY
: .I.>. .I.
REVISED: APR. 87
;“o”;; 1987-90
CHASSIS AND BODY
CHASSIS FRAME
Alignment check
Diagram reference
AA
BB
cc
DD
EE
FF
1
....
‘.
:.:.:..
..
2
3
4
5
6
7
8
9
10
11
12
13A
138
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Wheelbase-Reference dimension
Centre line of front axle
Centre line of rear axle
Frame datum line
Side member datum line
Datum line
(with mounting washers)
(without washers)
Reference dimension
To face of boss
Frame datum to underside of cross-member
Check figure
millimetres
inches
2540.00
100.000
254.00 + 0.63
263.525 + 1.91
- 0.63
261.11 2 2.54
266.70 + 2.54
237.74 4 1.27
327.81 f- 2.54
979.93 + 1.27
2244.72 + 2.54
356.74 + 2.54
605.15 + 2.54
1405.38 + 2.54
694.44 + 2.54
338.83 + 2.54
222.25 2 5.08
240.54 + 2.54
794.91
935.43 L 2.54
150.79
535.94 + 2.54
590.55 + 0.64
630.93 ~1.27
344.17 + 1.27
485.77 f 2.54
485.77 + 2.54
414.32 + 2.54
129.03 + 2.54
2544.44 + 0.25
1355.34 + 0.38
1722.04 + 0.38
2663.44 + 0.38
144.09 2 0.38
400.48 fL 2.54
1333.88 + 0.38
10.000 + ,025
10.375 + ,075
- ,025
10.180 + .I00
10.500 2.100
.9.360 + ,050
12.906 -f .I00
38.580 2.050
88.375 + .I00
14.045 +.100
23.825 +.I00
55.330 +-loo
27.340 +.I00
13.340 +.100
8.750 2.200
9.470 L.100
31.296
36.828 +.100
5.937
21.100 ~.I00
23.250 2.025
24.840 2.050
13.550 +.050
19.125 + .I00
19.125 + .I00
16.312 +.I00
5.080 +.I00
100.175 2.010
53.360 2.015
67.797 2.015
104.860 +.015
5.673 +.QlS
15.767 +.lOO
52.515 2.015
.
Continued
5
"
:
RANGE
1987-90 ROVER
CHASSIS AND BODY
millimetres
.c,.
32
33
34
Reference dimension
Reference dimension
Reference dimension
925.49
147.62
635.00
inches
36.437
.
5 . 8 1
25.000
SECTION XX
35
36
37
Frame datum line DD
488.95 r. 2.54
295.27 2 2.54
19.250 + .lOO
11.625 2.100
660.40 + 0.17
MO.95 + 1.91
- 0.63
26.000 L.007
3.187 + .075
-.025
80.95 + 1.91
- 0.63
660.4 + 0.17
9.525 + 2.54
3.187 + .075
-.025
26.000 _+_.007
0.375 &.I00
SECTION W
38
39
40
Frame datum line DD
SECTION ZZ
41
42
43
44
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:
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Frame datum line DD
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2
CHASSIS AND BODY
BODY
Introduction:
The information which follows is concerned solely
with the ‘Monocoque’ assembly of the inner body
shell on Range Rover models.
Body repairs
often
require the removal of
mechanical and electrical units and associated
wiring. Where necessary, reference should be made
to the relevant section of the Repair Manual for
removal and refitting instructions.
(76 1
Spot welding is satisfactory if the joints do not pull
apart. If the weld pulls a hole or tears the metal the
weld is satisfactory. It is defective if the weld joint
pulls apart or if there are signs of burning, porosity
or cracking evident.
PREPARATION
Thoroughly clean all areas to be welded, remove
any sealants and corrosion protectives from around
original panels. Align and clamp all new panels in
position and check relationship to one another.
Continued
The
inner
body
shell
is
of
construction and to gain access to the
may be necessary to remove exterior
all exterior body panels are bolted
body shell to facilitate easier panel
replacement or repair.
,.
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‘Monocoque’
repair area, it
body panels,
to the inner
removal and
It is expected that a repairer will select the best and
most economic repair method possible, making use
of the facilities available. The instructions given are
intended to assist a skilled body repairer by
expanding
procedures
for
approved
panel
replacement with the objective of restoring the car
to a safe running condition and effecting a repair
which is visually acceptable.
WELDING
The following charts and illustrations show the
locations and types of weld for securing the body
side assembly, tailgate frame assembly and the front
valance
Before
and
wheel
arch
assembly.
undertaking any spot weld joints to the inner body,
it is advisable to make a test joint using offcuts of
the damaged components, and to use this test
piece to perform a weld integrity test.
7
76 CHASSIS
l-l
RANGE
1987-90 ROVER
AND BODY
INNER BODY SHELL ASSEMBLY
JOINT (minimum number of
spot welds quoted)
LOCATION
FACTORY
A.
Front cross member to
valance and wheel arch
assembly
6 spot welds, 20mm pitch
B.
Hood locking platform to
valance and wheel arch
assembly
10 spot welds, 25mm pitch
C.
Valance and wheel arch
assembly to dash and tunnel
assembly
16 spot welds, 25mm pitch
0.
Body side complete to dash
and tunnel assembly
IO spot welds, 65mm pitch
R”o”v‘;l: 7 987-90
CHASSIS ANn Rnnv hiI
LOCATION E
LOCATION
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1.. .,
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LOCATION F
FACTORY JOINT (minimum number of
spot welds quoted)
.,:.
:
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E.
-.
1. Body side complete to
heelboard panel assembly.
2. Body side complete to
dash and tunnel assembly
complete.
3. Body side complete to dash
and tunnel assembly
I.
Body side complete to
dash and tunnel
assembly complete
2. Body side complete to
dash and tunnel
assembly complete
3. Body side complete to
dash and tunnel
assembly complete
14 spot welds, 35mm pitch
10 spot welds, 25mm pitch
3 spot welds, 30mm pitch
7 spot welds, 30mm pitch
18 spot welds, 40mm pitch
30 spot welds, 34mm pitch
Continued
9
76
.I
RANGE
1987-90 ROVER
CHASSIS AND BODY
LOCATION C
LOCATION
LOCATION H
FACTORY JOINT (minimum weld
requirement quoted)
G. 1. Reinforcement plate to
dash and tunnel assembly
and body side assembly
complete
CO, weld, 2 places 75mm long
each weld
H. 1. Body side complete to roof
header panel assembly
(internal joint)
2. Body side complete to roof
header panel assembly
(internal joint)
3 spot welds, 15mm pitch
3 spot welds, 15mm pitch
;:
LOCATION K
LOCATION J
LOCATION
FACTORY JOINT (minimum weld
requirement quoted)
I.
1. Body side complete to rear
tailgate frame assembly
CO? weld, one run 40mm long
K.
1. Body side complete to roof
header panel assembly
(external joint)
2. Body side complete to roof
header panel assembly
(external joint)
CO? weld, one run 20mm long
CO* weld, one run 100mm long
Continued
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1
1
76
l-l
CHASSIS AND BODY
1987-90 K:,:;
I
LOCATION L
LOCATION
L.
1. Body side complete to rear
tailgate side member
M. 1. Body side complete to rear
tailgate bottom cross
member
LOCATION M
FACTORY JOINT (minimum weld
requirement quoted)
32 spot welds, 30mm pitch
CO2 weld, 2 runs 40mm long
:..
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.,
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‘. ..,.,. :.:
:
.,
..‘_ ....
KANut
ROVER
CHASSIS AND BODY (76
1987-90
1
RR1562M
‘.’
LOCATION N
:I.
LOCATION
N. 1. Valance and wheel arch
assembly to dash and
tunnel assembly
2. Valance and wheel arch
assembly to dash and
tunnel assembly.
:
i’
JOINT (minimum number of
spot welds quoted)
FACTORY
4 spot welds, 45mm pitch
15 spot welds, 25mm pitch
.;;,,p:
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13
Y’
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/
76
HEADLINING AND ROOF PANEL
Remove and refit
Removing
Headlining
. . . ..
RANGE
1987-90 ROVER
CHASSIS AND BODY
1. Remove the two roof lamp assemblies.
2. Remove the rear view mirror and mounting
bracket.
3. Remove the two sun visors and centre
retaining bracket.
4. Remove the front and rear passenger grab
rails.
5. Pry out the two plastic retaining clips securing
the centre of the headlining to the roof panel.
6. With assistance support the front of the
headlining while releasing the two rear fixings
above the rear quarter light glass.
7. While the headlining is still being supported
pry out the two plastic retaining clips securing
the rear end of the headlining, located
adjacent to the upper tailgate hinges.
CAUTION: To avoid damage and to assist in the
removal of the headlining from the vehicle,
slightly flex the headlining as shown in the
illustration below.
8. Lower the headlining and disconnect the
electrical leads from the rear radio speakers,
remove the headlining from the vehicle.
Roof panel
9. Remove the screws (with washers) from
around the inner edge of the roof panel.
10. With assistance lift the roof panel from the
remove
previous
sealing
body,
any
compounds from around the edge of the roof
panel and body.
Refitting
11. Apply a waterproof sealant to roof and body
mating faces.
12. Reverse the removal instructions 1 to 9.
HOOD-COWL PANEL-FRONT FENDER
Remove and refit
Removing
CAUTION: The assisted hood lift mechanism
alone will not retain the hood in its fully open
position. Always secure the hood stay to support
an open hood.
Open the hood and disconnect the battery
negative terminal.
Disconnect the under-hood lamp electrical
leads.
Disconnect the windscreen washer tube at the
‘T’ joint.
Release the four bolts securing the hood to
the hinges, note the ground strap located
under the upper left hand hood fixing, with
assistance lift the hood clear of the vehicle.
Cowl panel
Remove the wiper arms and two nuts securing
the wheel boxes to the cowl panel and
remove the two exterior sealing rubbers.
Remove the nine cross-head screws securing
the front of the cowl panel.
Remove the four bolts (with spring and plain
washers) retaining the cowl panel to the top
of the fenders, retrieve the nylon spacing
washers from between cowl panel and fender.
:
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14
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R”o”v’;; 1 9 8 7
::’
CHASSIS AND BODY
‘.
..,.
RR2129E
8. Remove the four cross-head screws retaining
the panel to the ‘A’ post mounting brackets
located above the front door hinges.
9. With assistance place a tube over each of the
hinges and lower to enable the cowl panel to
be fed over the hinges, carefully return the
hinges to their upright position.
,’
,
:
Refitting
Front fender
._
,’
16. Remove the two bolts (with plain washers)
securing the sill finishing strip to the bottom
of the fender.
17. Remove the two cross-head screws securing
the fender to the mounting bracket attached
to the ‘A’ post located in between the front
door hinges.
10. Remove the two cross-head screws from the
top of the front side light assembly, maneuver
the assembly out of the two bottom location
holes.
11. Remove the bulb holder waterproof cover,
depress the two retaining clips and withdraw
the bulb holder from the rear of the lamp unit.
Remove the lamp unit.
12. Remove the two screws (with plain washers)
from the bottom of the side light recess.
13. Remove the three fixings securing the bumper
wrap around end cap and remove the
moulding from the bumper.
14. Remove the bolt which secures the end of the
spoiler to the front of the wheel arch, located
forward of the road wheel at the bottom of
the fender.
15. Remove the five nuts and bolts (with plain and
spring washers) securing the top edge of the
fender to the wheel arch and valance
assembly.
Front fender
18. Apply a suitable underseal to the inner face of
the fender and a waterproof sealant to the
fender to wheel arch/valance mating faces.
19. Ensure that before final tightening of the
fender securing bolts the fender aligns with
the edge of the front door.
20. Reverse remaining fender removal instructions.
REVISED: JULY 88
Continued
.
15
1 9 8 7 lWNGt
ROVER
CHASSIS AND B O D Y
.‘.
:
Cowl panel
21. Lower the hinges to enable the cowl panel to
be fitted.
22. Fit the securing bolts ensuring that any nylon
.’
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x
spacers previously removed are refitted in their
original position.
23. U s i n g a s o f t b l u n t i m p l e m e n t e a s e t h e
windscreen rubber up onto the top of the
cowl panel.
24. Reverse the remaining cowl panel removal
instruction.
NOTE: An engine ground strap is attached to the
forward bolt of the left hand hinge and must be
refitted when the hood is re-bolted to the
hinges.
6. With assistance lift the hood clear of the
hinges and store safely to one side, cover
hood to protect paintwork.
Hood
25. F i t t h e h o o d e n s u r i n g t h a t b e f o r e f i n a l
tightening of the securing bolts, the engine
ground strap is refitted to the forward bolt of
the left hand hinge, and that the hood aligns
with the cowl panel, fender and front grille,
adjust the hood at the hinges as necessary.
26. Reverse the remaining removal instructions.
ASSISTED HOOD LIFT
:
Remove and refit
7. Remove the two wiper box wheel nuts and
Removing
8. Remove the four fixings securing the cowl
rubber spacers.
CAUTION: The assisted lift mechanism of the
hood eases the hood opening and lift procedure.
When the hood is fully open, secure the hood
stay in position. The assisted lift mechanism
alone WILL NOT retain the hood in its upright
position.
panel to the front fenders, the front two
fixings are accessible from the front of the
cowl panel, access to the rear two fixings is
gained by opening the front doors. Note the
nylon spacing washers at each bolt.
Carefully pry the wiper arms off the spindle
bosses, noting their position for re-assembly.
Raise the hood and disconnect the battery
negative terminal.
Disconnect the electrical lead to the hood
illumination lamp.
Disconnect the screen washer fluid feed pipe
at the IT’ joint, remove the feed pipe from the
hood retaining clip.
‘..
.
:
NOTE: The removal of the hood will require the
assistance of a second person.
5. Release the four bolts (with plain washers)
securing the hood to the hinges.
16
9. Remove the nine cross-head screws from the
front of the cowl panel water channel.
REVISED: JULY 88
:.
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;:I..
PO;;; 1 9 8 7
10. Place extension tubes over each hood hinge,
with assistance lower the hinges,maneuver the
cowl panel off the wiper arm shaft bosses and
along the tubes until the panel is clear of the
vehicle. Place the panel to one side and cover
to protect paintwork.
WARNING: Gradually let the torsion bar spring
tension return the hinges to their upright
position to prevent the possibility of personal
injury or damage to the vehicle.
11. Place an extension tube over the hinge, lower
the hinge until the stop bracket can be
removed, withdraw the bracket and gradually
allow the hinge to return to its upright
position.
:
‘.
CHASSIS AND BODY
15. Remove the two bolts (with plain washers)
securing the hinge to its mounting bracket.
16. Withdraw the hinge.
Refitting
17. Fit the hinge and securely tighten the two
retaining bolts (with plain washers).
18. Fit the torsion bar ensuring that it is securely
located in the retaining clip and bracket.
I 9. Reverse the remaining removal instructions.
NOTE: Fit the ground strap under the forward
bolt of the left hand hinge.
20. Using a soft blunt implement ease the bottom
lip of the windscreen seal up and over onto
the face of the cowl panel.
12. Release the torsion bar from the retaining clip.
13. M a n e u v e r t h e t o r s i o n b a r u n t i l i t c a n b e
released from the hinge.
14. Release the torsion bar from the retaining
bracket.
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17
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RANGE
“*’ R O V E R
CHASSIS AND BODY
:
REAR CORNER PANEL AND FENDER
Remove and refit
CAUTION: IF A REPAIR IS BEING UNDERTAKEN
ON OR AROUND THE AREA OF THE REAR RIGHT
HAND FENDER AND HEAT IS TO BE APPLIED,
THE FENDER MUST BE REMOVED, AS A FUEL
EXPANSION TANK IS LOCATED BETWEEN THE
FENDER AND INNER BODY SIDE.
Removing
NOTE: Ensure the central locking system is
de-activated to enable the fuel filler flap to be
disconnect the battery negative
opened,
terminal.
I. Open the fuel filler flap and remove the three
filler tube securing screws.(Right hand rear
fender only)
RR2130E
..
2. Remove the rear stowage area parcel shelf and
spare wheel.
3. Remove the two nuts (with washers) securing
the bumper wrap around end cap to the
bottom of the corner panel.
4. Remove the single bolt securing the end cap
to the bumper, accessible from behind the
bumper.
5. Remove the fixings and release the rear tail
light cluster from the rear corner panel and
disconnect the electrical plug.
6. Drill out all the pop-rivets securing the corner
panel to the tailgate frame.
7. Remove the two nuts and bolts securing the
front of the fender to the ‘D’ post located
beneath the wheel arch.
8. Release the single nut and bolt retaining the
mud-flap bracket to the bottom of the fender.
9
From inside the slowage area remove the five
cross-head screws securing the top of the
fender to the bodyside panel. If necessary fold
the rear seat forward and remove the seat
locking mechanism housing to gain access to
the screw adjacent to the ID’ post.
10. Remove the rear fender and comer panel
complete.
11. Remove the seven bolts (with plain and spring
washers) securing the fender to the corner
panel and separate the two panels.
Refitting
12. Assemble the corner panel to the rear fender,
fit the bolts and ensure both panels align
before final tightening.
. .
;“d”;; 1 9 8 7
13.
Coat the underside of panels with a suitable
underseal.
14. Fit the assembly to the vehicle ensuring that
the door edge to fender edge and corner
panel to lower tailgate are in alignment before
the fina; tightening of screws and the fitting of
pop-rivets.
15. Reverse the remaining removal instructions.
FUEL FILLER FLAP
Remove and refit
Adjust
Removing
NOTE: The fuel filler flap is locked when the
central locking system has been
vehicle
system
ensure
has
been
activated,
the
de-activated before attempting to open the flap.
...>
CHASSIS AND BODY rid
REAR QUARTER PANEL-INTERIOR
Remove and refit
Removing
NOTE: If removing the drivers side interior
quarter
panel
it
will
be
or exterior
necessary to remove the spare wheel from
the rear stowage area.
1. Detach the plastic cover from the upper seat
belt guide bracket and remove the single bolt.
2. Remove the clip-on plastic cover from the seat
belt inertia reel. Remove the retaining bolt and
place the inertia reel to one side.
3. Release the two small cross-head screws
securing the trim panel to the body side.
4. Ease the front of the trim panel from behind
the quarter light glass rubber moulding.
5. Withdraw the panel from the vehicle.
I.
Open the fuel filler flap.
2. Release the two screws (with plain washers).
3. Withdraw the flap.
Refitting
RR2073E
Refitting
4. Fit the flap, but do not fully tighten the screws
at this stage.
5. Close the flap and check that the outer profile
of the flap aligns with the rear fender, adjust
by easing the flap in or out of the opening.
6. Open the flap and securely tighten the screws.
Ease the top front edge of the trim panel
(approximately the first 25mm, 1 inch) as close
to the headlining as is possible under the lip
of the rubber moulding.
Push the panel up behind the headlining until
the cross head screw holes line up with their
respective holes in the bodyside.
Using a soft blunt implement ease the rubber
moulding lip over the remainder of the front
of the trim panel.
Continued
,_..’
‘.
;
19
1987 ;;rv;r;
CHASSIS AND BODY
9. Ensuring that the electrical harness is located
in the channel at the rear of the trim panel fit
the two crosshead screws.
10. Ensuring that the seat belt is not twisted fit the
guide bracket and inertia reel, tighten the two
bolts to the specified torque (see section
06.Torque values).
71. Refit the plastic cover to the guide bracket.
REAR QUARTER PANEL-EXTERIOR
Remove and refit
Removing
NOTE: If removing the drivers side interior
or exterior quarter panel it will be
necessary to remove the spare wheel from
the rear stowage area.
:.
1. Remove the rear seat belt inertia reel and
::
:
.’
guide bracket.
2. Remove the two crosshead screws and detach
the interior quarter panel.
3. Remove the three nuts (with plain washers)
securing the exterior quarter panel to the
bodyside. The nuts are accessible through the
large holes located adjacent to the rear quarter
light.
4. Remove the four screws securing the quarter
panel to the inside edge of the tailgate
opening.
5. Withdraw the panel.
:
Refitting
6. Reverse the removal instructions.
7. Ensure that the seat belts, inertia reel and
guide bracket bolts are tightened to the
specified torque (see section 06-Torque
values).
:
,‘.
FOE;
‘. ‘.‘.
’ ,:.I ; ’
i.,, , b
..‘:v’,“...+
1987
CHASSIS AND BODY
UPPER TAILGATE
UPPER TAILGATE-LOCK
Remove and refit
Remove and refit
Removing
Removing
Disconnect the battery negative lead.
Remove the tailgate wiper arm.
Open the tailgate and remove the four screws
securing the two rear screen electrical lead
shrouds located at either end of the tailgate.
Maneuver the shroud away from the screen
and out of the leadlining to reveal the
electrical connections, disconnect the leads.
1. Remove the two cross-head screws securing
the upper tailgate release handle.
2. Ease the sealing rubber away to reveal the
single screw securing the centre of the release
handle, remove the screw and detach the
handle from the lock mechanism complete
with key barrel.
WARNING: If a tailgate stay is weak, DO NOT
attempt to repair the unit. Fit a replacement.
.
.
‘; .(
5. Pry the two stays off the tailgate.
6. Remove the four hinge to tailgate screws.
RR1622M
-
i
II
II
NOTE: At this stage the barrel can be
removed from the handle by releasing the
two small cross-head screws at the
joint-face. Remove the retaining plate and
release the spring and key barrel from its
bore.
7. Lift the upper tailgate clear.
Refitting
3. Release the eight screws and remove the
operating rod covers located either side of the
centre lock mechanism.
4. Remove the four screws and two nuts securing
the lock catches to the sides of the tailgate.
8. Reverse the removal instructions.
RR1623M
//
Continued
21
1987 IWNbt
ROVER
CHASSIS AND BODY
,
,,., :
5. Release the two small locknuts on the
operating rods and rotate the hexagonal
connecting rod until the side catches can be
removed.
6. Release the two screws securing the centre
lock mechanism and remove the unit
complete with operating rods.
Refitting
7. Reverse the removal procedure.
8. Adjustment of the side catches may be
required after assembly, this is achieved by
releasing the locknuts on the operating rods,
and rotating the hexagonal link clockwise or
counter-clockwise to shorten or extend the
length of the operating rods.
LOWER TAILGATE
Remove and refit
Removing
1. Disconnect the battery negative terminal.
2. Carefully pull the electrical leads out of the
bottom of the lower tailgate to reveal the snap
connectors. Access to the leads is gained
between the top of the bumper and bottom
of the tailgate.
2
,:’
:,
‘.
.,
RR2 143E
Remove the four cross-head screws securing
the sealing rubber around the tailgate hinge
bolts.
Remove the fixings, tailgate to hinges.
Disconnect the check straps.
With assistance withdraw the tailgate.
RR2144E
defitting
7. Reverse 1 to 5.
8. Ensure that the rubber grommet is relocated in
the bottom of the tailgate.
.22
. . . .,
j
ro;;l;
1987
CHASSIS AND BODY
.;.:..
176
1
...
LOWER TAILGATE RELEASE MECHANISM
Remove and refit
Removing
‘.‘.
1.
2.
3.
4.
5.
6.
.a
‘,,,
7.
8.
,;.:,,
Open and raise the upper tailgate.
Release and lower, the lower tailgate.
Lift the trim panel off the tailgate inner panel.
Remove the screws securing the lock cover
plate.
Remove the cover plate complete with handle
release mechanism.
Remove the two screws and detach the handle
release actuator lever.
Remove the two nyloc nuts and detach the
handle release retaining bracket.
Withdraw the handle release mechanism from
the cover plate.
Refitting
12. Reverse the removal procedure, lightly grease
the handle release actuator lever and internal
tailgate operating lever.
LOWER TAILGATE STRIKER ADJUSTMENT
Adjust
1. Open and raise upper tailgate.
2. Open and lower, lower tailgate.
in
the
move
the striker and
3. Release
appropriate direction, either add or subtract
spacing washers between the striker and
tailgate opening.
4. Adjustment is correct when outer profile of
tailgate panel aligns with both rear body
corner panels.
\
.1.x.
:
..,
\
\
I
..
RR2001E
9. Release the spring clips securing the operating
internal
rods
to
the
tailgate
release
mechanism.
10. Remove the screws securing the exterior locks
at either side of the tailgate.
11. Withdraw the exterior locks with operating
rods.
23
RANGt
76 CHASSIS AND BODY
l-l
“*’ ROVER
RADIATOR GRILLE
FRONT DOOR
Remove and refit
Remove and refit
Removing
Removing
1. Raise the hood and secure the hood support.
2. Depress the four upper retaining lugs and ease
the grille forward.
3. Lift the grille upwards and withdraw it from
the vehicle.
1. Disconnect the battery negative lead.
2. Open the appropriate door to be removed.
3. Remove the two screws and detach the side
trim panel from the front footwell.
4. Carefully pull the door wiring harness from
above the dash until the electrical plugs are
exposed.
Disconnect the electrical plugs and feed them
through the opening in the ‘A’ post.
Drive out the roll pin from the door check
strap.
With assistance support the door and remove
the screws, securing door to hinges.
Lift the door clear.
Refitting
4. Fit the radiator grille ensuring that the bottom
lugs of the grille locate in their respective slots
below the headlamp units.
5. Ease the grille rearwards and locate the upper
retaining lugs.
Refitting
9. Refit the door and feed the electrical cables
through the ‘A’ post.
10. Fully open the door and reconnect the
electrical leads, take up the slack in the leads
and clip them securely to the footwell side
panel, refit the convolute grommet to the ‘A’
post frame.
11. Check the location of the door and the
operation of the door lock. If necessary, adjust
the door and striker plate.
:
.,’
:.
:
2
4
. . :
‘.’
::,_ .:i ;
::,,... .
ro;;; 1987
.‘,.,
:a ‘:
:,
‘:;,’
CHASSIS AND BODY bii
12. Adjust the door by the addition of shims
between the hinge and door or hinge and ‘A’
post to take the door forward or rearward in
the opening.
13. By loosening the six screws securing the
hinges to the door, the door can be adjusted
up and down or in and out of the opening.
,. : :
14. The door lock striker can be adjusted by
loosening the striker and moving it in the
appropriate
direction or
adding
and
subtracting spacing washers between the
striker and ‘B’ post.
FRONT DOOR GLASS AND REGULATOR
Remove and refit
Removing
.
1. Ensure the window is in its fully closed
position and secure it with adhesive tape to
prevent the window dropping down.
2. Disconnect the battery negative terminal.
3. Detach the armrest/door-pull finisher to reveal
the two securing screws.
4. Remove the two securing screws (with plain
washers) to enable the armrest/door-pull to be
detached from the inner door panel.
5. R e m o v e t h e i n t e r i o r d o o r h a n d l e f i n i s h e r
button to reveal the screw retaining the
handle surround.
6. Remove the screw and detach the handle
surround from the inner door panel.
7. Detach the inner door trim pad by inserting a
screwdriver between the trim pad and inner
door panel, gently pry out the nine plastic
securing clips from their respective holes in
the inner door panel.
8. Disconnect the two speaker connections
inside the door and remove the door trim pad
complete with speaker.
9. Remove the plastic vapor barrier.
10. Remove the window lift motor (refer to
Electrical Section).
Ii. Remove the four window regulator retaining
bolts with shakeproof washers from the inner
door panel.
.:,
1
RklEh38M ’
I I
Continued
.
‘....
..:
..‘.
25
‘,..,
,987
CHASSIS AND BODY
Remove the two screws with shakeproof
washers retaining the lower window lift
channel and slide the channel off the stud.
Disengage the lifting arm stud from the upper
window
maneuver
the
channel,
lifting
regulator and remove if from the lower centre
opening in the inner door panel.
KANLt
ROVER
20. Remove the bolt (spring and plain washer)
from the recessed hole in the front of the
inner door panel under the exterior driving
mirror mounting plate.
21. Remove the single screw (spring and plain
washer) from inside the door securing the
bottom front glass channel.
Remove the single screw (spring and plain
washer) from inside the door securing the
bottom rear glass channel.
23. Lift the door glass frame complete with glass
out of the door panel and remove to a
suitable bench.
24. Remove the adhesive tape securing the glass
to the frame.
25 Slide the glass out of the door frame channel.
.. -
Refitting
26. Reverse the removal instructions, items 1 to
25.
14. Remove the sill locking knob.
15. Remove the inner door capping off its keyhole
location.
16. Remove the exterior driving mirror (refer to
exterior driving mirrors removal and refit in
Electrical Section).
17. Remove the waist rail seal from the top of the
door panel.
NOTE: When refitting the door glass frame,
ensure it is repositioned to suit the door
opening before fully tightening the door
frame securing bolts.
FRONT DOOR LOCK, OUTSIDE AND INSIDE
DOOR RELEASE HANDLES
Remove and refit
Removing
‘i.
i
18. Remove the two bolts fshakeproof and plain
washers) from the hinge face of the door
which secure the front door frame.
19. Remove the single bolt (spring and plain
washer) from the edge of the door which
secures thd door rear frame.
2
6
1. R e m o v e t h e w i n d o w l i f t m o t o r ( r e f e r t o
Electrical Section).
2. Remove door glass and regulator (refer to
door glass and regulator remove and refit).
3. Remove door actuator units (refer to Electrical
Section).
4. Disconnect the control rod from the private
key operated lock by releasing the metal clip
at the bottom of the rod.
5. Disconnect the control rod from the outside
door release handle by pulling it out of the
plastic ferrule.
..
ro;$ 1987
.!
connector
rod
6. Disconnect the
control
between the inside door release handle and
the door lock by releasing the metal clip and
pulling one of the control rods out of the
plastic connecting block. This is accessible
through the small centre cut-out in the door
panel. (The control rod also passes through a
guide bracket on the inside of the inner door
panel).
7. From inside the door panel push out the small
pin which secures the quadrant to the inner
door panel. Push the quadrant out of the
panel.
8. Release the door lock by removing the two
counter-sunk screws from the door edge and
the single screw (with shakeproof washer) on
the inner door panel.
9. Withdraw the lock through the lower rear
cut-out on the inner door panel.
NOTE: If necessary the following items can
also be removed.
CHASSIS AND BODY
10. Remove t h e t w o n u t s ( w i t h s h a k e p r o o f
washers) and retaining bracket securing the
outside door release handle to the outer
door panel, accessible through the upper rear
cut-out on the inner door panel.
11. Carefully detach the door release handle from
the outer door panel.
12. Remove the two screws securing the inside
door release handle to the inner panel.
13. Withdraw the handle from its location with
half the connecting rod still attached.
14. Unclip the spring tensioned end of the
connecting rod from the door release handle.
Refitting
15. Reverse the removal procedure items 1 to 13.
NOTE: When refitting the door glass frame,
ensure that it is positioned to suit the door
opening before fully tightening the door
frame securing bolts.
. ..b
27
RANGE
lg8’ ROVER
CHASSIS AND BODY
ADJUSTMENT-FRONT DOOR LOCK AND HANDLE
ASSEMBLY
REAR PASSENGER DOOR
Remove and refit
Inside door release handle to lock
Removing
1. Refit the inside door release handle surround
before any adjustment is made, allowing the
handle to be set from the correct operating
position.
2. Rotate the spring tensioned nyloc nut at the
opposite
interior
end
of
the
handle
connecting
clockwise
rod,
01
counter-clockwise to shorten or extend the
operating length.
Outside door release handle to lock
3. Disconnect the connecting rod at the rear of
the outer door release handle by releasing it
from the plastic ferrule rotate the rod
clockwise or counter-clockwise to shorten or
extend the operating length, refit the rod to
the ferrule.
1. Disconnect the battery negative lead.
2. Pull the convolute grommet out of the face of
the ‘B’ post.
3. Withdraw the electrical leads from the ‘B’ post
until the electrical plugs are exposed and
disconnect the plugs.
4. Remove the two bolts (with spring and plain
washers) securing the door check strap.
5. Open the door slightly, support the door and
remove the six bolts (with spring washers)
securing the hinges to the ‘B’ post.
6. Lift the door clear.
NOTE: Door release should be effective
before the total handle movement is
exhausted to provide a small overthrow
movement.
Refitting
Reverse the removal procedure.
Adjustment to the rear doors is made by
releasing the six hinge securing bolts (hinge to
‘B’
post) and moving the door either
rear-wards. forward, up or down in the door
opening.
Adjustment to the door striker is identical to
front door adjustment.
,
;^d;‘;r; 1 9 8 7
CHASSIS AND BODY
14. Carefully disengage the lifting arm stud from
the glass lifting channel and remove the
window regulator from the lower opening in
the inner door panel.
REAR DOOR GLASS AND REGULATOR
Remove and refit
Removing
2.
3.
4.
5.
6.
I
7.
8.
9.
10.
11.
12.
13.
Ensure the window is in its fully closed
position and secure it with adhesive tape over
the top of the door to prevent the window
dropping down.
Disconnect the battery negative terminal.
Remove the armrest/door-pull finisher to reveal
the two securing screws.
Remove the two securing screws (with plain
washers) and detach the armrest/door-pull
from the inner door panel.
Disconnect the window lift switch multi-plug
at the rear of the armrest/door-pull.
Remove the interior handle finisher button 10
reveal the screw retaining the handle surround.
Remove the screw and detach the handle
surround from the door trim pad.
Remove the door trim pad by inserting a
screwdriver behveen the trim pad and the
inner door panel, gently pry out the six plastic
clips from their respective holes around the
edges of the trim.
Remove the sill locking button.
Remove the inner door capping from its
keyhole location.
Remove the plastic vapor barrier.
Remove the window lift motor (refer to
Electrical Section).
Remove the four window regulator securing
screws (with shakeproof washer).
15. Remove the waist rail seal from the top of the
door panel.
16. Remove the single bolt (with spring and plain
washers) from inside the door which secures
the bottom of the short rear glass run channel.
17. Remove the two bolts (with spring and plain
washers) from the hinge face of the door.
18. Remove the two bolts (with spring and plain
washers) from the edge of the door which
secure the rear door frame.
19. Lift out the door frame with the glass in
position and remove to a suitable workbench.
20. Remove the tape and slide the glass out of the
door frame channel.
NOTE: When refitting the door glass frame
securing bolts, ensure that the door frame
is adjusted to suit the door opening before
fully securing the frame to the door.
Conticued
REVISED: DEC. 87
29
‘. I..
l-l
76
1 9 8 7 ro;;;
CHASSIS AND BODY
REAR DOOR LOCK, OUTSIDE AND INSIDE DOOR
RELEASE HANDLES
7. Withdraw the lock through the upper rear
opening in the inner door panel.
NOTE: If necessary the following items can
also be removed.
Remove and refit
Removing
1. Ensure the window is in its fully closed
position.
2. Remove all the interior door trim (refer to
door glass and regulator remove and refit,
items 2 to 11).
3. Disconnect the control rod from the inside
door release handle by pulling the rod out of
its location at the door lock.
4. Disconnect the sill locking control rod from
the door lock by releasing the metal clip.
5. Disconnect the control rod from the outside
door release handle by pulling it out of the
plastic ferrule.
6. Release the door lock by removing the two
counter-sunk screws from the door edge and
the single screw (with shakeproof washer) on
the inside of the door. Retrieve any spacing
washers which may be fitted between the
inner door panel and the lock.
8. Remove t h e t w o n u t s ( w i t h s h a k e p r o o f
washers) and retaining bracket securing the
outside door release handle to the outer
door panel, accessible through the upper rear
cut-out on the inner door panel.
9. Carefully detach the outside door release
handle from the outer door panel.
10. Remove the two screws (with plain washers)
securing the inside door release handle to
the inner door panel.
11. Withdraw the handle from its location with the
connecting rod still attaclred.
12. U n c l i p t h e s p r i n g t e n s i o n e d e n d o f t h e
connecting rod from the door release handle.
REVISED: DEC. 87
Continued
po;g 1 9 8 7
Sill locking quadrants
13. Use a-small screwdriver, or 3.175mm diameter
(l/8 in) rod, press the plastic locking pins
through the respective square inserts in the
inner door panel, until they can be retrieved
from inside the door.
14. Release the quadrants from the inner door
panel and unhook the respective connecting
rods.
15. Withdraw the quadrant from inside the door.
NOTE: When refitting the quadrants the
plastic locking pins are entered into the
square insert from outside and pressed in
flush.
CHASSIS AND BODY
ADJUSTMENT-REAR DOOR LOCK AND HANDLE
ASSEMBLY
Outside door release handle to lock.
l.Disconnect the short offset connecting rod
at the rear of the outer door release handle,
rotate the rod clockwise or counter-clockwise
to shorten or extend the operating length.
NOTE: Door release should be effective
before the total handle movement is
exhausted to provide a small over-throw
movement.
Refitting
.,:
1761
16. Reverse the removal procedure 1 to 15.
,
//
m216aE
!,
! :
/
76
CHASSIS AND BODY
WINDSCREEN CLASS
Remove and refit
Removing
CAUTION: Place a protective covering over the
cowl panel and dashboard to prevent damage to
the bodywork and also to prevent broken glass
entering the heater system.
RANGE
lg8’ ROVER
11. Work the glass into the bottom of the
soft
blunt
windscreen
rubber
using a
implement shaped with a wedge type point,
working up and around the seal and at the
same time pushing the screen onto the
rubber, ease the lip of the seal over the
windscreen glass as illustrated.
‘..
1. Remove the windscreen wiper arms.
2. Remove the expander strip from the channel
in the rubber moulding around the glass.
3. Remove t h e r u b b e r m o u l d i n g f r o m t h e
windscreen opening.
4. Remove any previous sealing compound from
around the opening.
5. Thoroughly clean the windscreen opening and
remove any broken glass.
Refitting
CAUTION: To ensure a good bond is achieved
between windscreen and rubber DO NOT use
petroleum based solvents or liquid soap to clean
or aid assembly of the windscreen to rubber.
6. Apply Sikaflex 207 cleaner primer to the
windscreen and rubber to remove any oil
based film that may be present.
7. Apply Sikaflex 221 or 255 adhesive sealant to
the exterior channel of the NEW rubber
moulding, ensure the sealant is applied to the
bottom of the channel.
8. Fit the rubber moulding to the windscreen
opening.
9. Ensure that the edge of the ‘A’ post interior
trim panels are fitted under the lip of the
rubber moulding.
IO. Fit the windscreen into either bottom corner
of the rubber moulding channel.
12. Apply Sikaflex 221 or 255 adhesive sealant
between the outer lip of the rubber moulding
and exterior surface of the windscreen, ensure
the sealant is applied to the bottom of the
channel.
CAUTION: To aid assembly of expander strip to
the windscreen rubber apply a small amount of
soap solution to the channel on the face of the
rubber. Ensure that the soap solution is applied
to the.channel only.
-. . . .
1
‘*,
13. To aid insertion apply mineral spirit to the
rubber expander strip channel.
32
:
PO;;; 1987
Fit the expander rubber to the channel, do not
overstretch the rubber.
If any of the rubber strip protrudes beyond
the channel after fitting, trim off at 45” with a
sharp knife.
CHASSIS AND BODY
REAR QUARTER LIGHT GLASS
Remove and refit
Removing
1. Remove the rubber moulding from around the
glass opening.
2. Thoroughly clean the opening to be glazed.
NOTE: If a new glass and moulding is being
fitted to the driver’s side quarter light it will
be necessary to remove the spare wheel.
Refitting
RR2151E
16. Surplus sealant between screen and rubber
moulding will be forced out after the expander
strip is fitted.
17. Remove the surplus sealant, and wipe away
the remaining sealant using Sikadur cleaner.
18. With a blunt instrument lift the bottom of the
rubber moulding up and over onto the top of
the cowl panel, likewise repeat the operation
to bring the bottom of the rubber moulding
up and over onto the dashboard.
19. Refit the wiper arms, check the wiper sweep is
correct.
20. Reverse the remaining removal instructions.
TAILGATE CLASS
Remove and refit
Removing
1. Remove the upper tailgate.
2. Remove the lock.
3. Remove the lift handle and trim.
4. The upper tailgate glass and frame are serviced
as one unit.
Refitting
5. Reverse instructions 1 to 3.
3. Fit the new moulding to the glass.
4. Fit a draw cord around the exterior surface of
the rubber moulding ensuring that it sits
securely in the bottom of the moulding
retaining channel.
5. Coat the glass opening in the body side with
liquid soap to aid assembly.
6. Fit the glass and moulding to the glass
opening ensuring that the draw cord is fed
into the interior stowage area.
NOTE: It may be necessary to remove the
seat belt inertia reel and cover.
7. With assistance from a second operator
pushing the glass and moulding into the
opening pull the draw cord from the moulding
enabling the seal to ride up over the bodyside
retaining lip.
8. Ensure the interior trim lies under the rubber
moulding.
76
1987 RANGE
ROVER
CHASSIS AND BODY
FRONT SEAT
Remove and refit
Removing
1. Remove the single screw securing the seat
base side trim panel and withdraw the panel.
2. Remove the three screws securing the seat
base front trim panel to the front footwell,
remove the single screw securing the top of
the front trim panel to the seat base located
under the seat base cushion, and withdraw the
panel.
3. Remove the three fixings securing the seat
cushion side trim panel and withdraw the
panel. Remove the bolt securing the seat belt
to the side of the seat.
4. Move the seat until it is in its most rearward
position.
5. Remove the two fixings securing the front of
the seat located in each seat slide channel.
6. Move the seat until it is in its most forward
position.
7. Remove the four fixings securing the rear of
the seat located inside each seat slide channel.
8. Disconnect the battery negative terminal.
9. Disconnect the electrical multi-plugs to the
seat motors and seat control switch.
10. Withdraw the seat from the vehicle.
11. If necessaqr the seat motors and operating
switch can be removed. (Refer to Section 86
Electrical).
Refitting
12. Reverse the removal instructions.
13. Arrange the electrical leads beneath the seat
to ensure that they do not become trapped b)
the seat slide mechanism.
RR2152E
. .
,.’
,,‘. ‘<
PO;:;
1987
CHASSIS AND BODY
ASYMMETRIC SPLIT REAR SEAT
Refitting
5. Reverse the removal procedure ensuring that
all fixings are securely tightened.
6. Adjust the seat mechanism plate if necessary.
Remove and refit
Removing
1. Lift the finger button to release the seat back
rest securing catch and fold the seat forward.
2. While folding the seat forward feed the rear
seat lower part of the seat belt through the
opening between the seat back and cushion.
ASYMMETRIC SPLIT REAR SEAT
LOCKING MECHANISM
Remove and refit
Removing
I. Lift the finger button and fold the seat back
rest forward.
2. Remove the spring clip securing the finger
button operating rod to the lock mechanism
lever, accessible through the lock mounting
bracket, withdraw the finger button.
..
‘.
3. Fold the seat fully forward and remove the
four rear pivot bracket bolts.
4. Fold the seat back and lift the rear footwell
carpet from just below the front of the seat to
gain access to the four front fixings securing
the pivot brackets, remove the bolts, withdraw
the seat assembly from the vehicle.
RR2058E
3. Remove the trim stud and remove trim
covering.
4. Remove the three screws from the face of the
lock catch plate.
5. Maneuver the catch plate off the lock
mechanism.
6. Retrieve t h e l o c k . m e c h a n i s m f r o m t h e
mounting bracket opening.
Continued
RR2057E
4
\.
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REVISED: JULY 88
35
RANGE
“*’ ROVER
I
76
CHASSIS AND BODY
ASYMMETRIC SPLIT REAR SEAT
LOCKING MECHANISM
‘.
Adjust
1. Release the finger button and fold the seat
back rest forward.
2. Loosen the three screws securing the catch
plate to the lock mechanism.
either
assembly
lock
the
3. Maneuver
horizontally, vertically or diagonally until the
catch plate aligns with the striker at the side of
the seat.
4. Securely tighten the retaining screws.
Refitting
7. Lightly grease the internal lock mechanism.
8. Reverse the removal instructions.
9. Adjust the lock catch plate to align with the
seat striker.
i
RR2060E
3
6
REVISED: JULY 88
CHASSIS AND BODY
A-
SEAT BELTS
Description
,.‘I ,:
..s
*.:
The seat belt assemblies are factory fitted in the
correct location. If removal is necessary the
procedures in this section must be followed. Afl
seat belt fixings MUST be tightened to the correct
torque (see section 06-Torque values).
Seat belt assemblies MUST be replaced after they
have been subjected to loading by occupants in a
collision. Where replacement is necessary, the
original manufacturer’s components must be used.
An audible warning and warning lamp are
incorporated in the system.The warning lamp will
illuminate for eight seconds when the ignition is
switched on regardless of seat belt usage.
The audible warning will sound with an intermittent
high and low note for four to eight seconds unless
the driver’s seat belt is used.
RR2 163E
\\
3. Remove the plastic cover and remove the bolt
securing the belt to the rear wheel arch.
A single lap belt is provided for the occupant of the
centre rear seat.
REAR SEAT BELT
I
8’
.::
Remove and refit
Removing
.,
1. Detach the plastic cover from the upper seat
belt guide bracket and remove the securing
bolt, plain and wavy washer and spacer.
2. Remove the clip-on cover from the inertia reel
assembly. Remove the securing bolt and
spring washer and place the reel to one side.
4. Withdraw the assembly.
Continued
37
,.
:
CHASSIS AND BODY
‘.
.’
.,
56
::
”
,(A’.,
‘,
‘.
:
:
RR2166E
5. Working behind the rear seats, remove the
bolt and plain washer and withdraw the buckle
assembly.
6. Centre lap strap only: working behind the rear
seats, remove the bolts securing the lap strap
and the buckle assembly and withdraw both
components.
Refitting
.:
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7. Reverse the removal procedure ensuring that
the harnesses are not twisted. Finally tighten
the fixings to the correct torque (see section
OC-Torque values).
::,
‘.’
3
:.
38
.:
:....
‘Y
‘.’
RANGE
“*’ ROVER
;;;t: 1 9 8 7
CHASSIS AND BODY
RR2102E
10. Disconnect the electrical connection and
remove the bolt securing the buckle to the
seat base.
FRONT SEAT BELT
. ...’
Remove and refit
Refitting
Removing
:.I
1. Adjust the front seat to the mid-position.
2. Disconnect the battery negative lead.
3. Remove the seat cushion side trim panel - see
Front Seat - remove and refit, page 34, Section
76.
4. Remove the bolt, plain washer and spacer
securing the belt to the seat base.
5. Remove the moulding from the adjustable seat
belt mounting.
6. Remove t h e s h o u l d e r e d n u t a n d s p a c e r
securing the seat belt to the ‘B’ post.
7. Remove the two screws securing the trim
finisher and release the finisher from the belt.
8. Ease the door seal away and remove the lower
‘B’ post trim casing.
9. Remove the bolt and spring washer securing
the inertia reel assembly to the ‘B’ post and
withdraw the assembly.
I 1. Reverse the removal procedure ensuring that
the belt is not twisted. Finally tighten the
fixings to the correct torque (see section
06-Torque values).
REVISED: APR. 87
39
RANGE
lg8’ ROVER
CHASSIS AND BODY
CLOVE BOX AND FLOOR MOUNTED CONSOLE
ASSEMBLY
FRONT DOOR STOWAGE BINS
-. .
Remove and refit
Remove and refit
Removing
Removing
1.
Remove the seven fixings securing the
stowage bin to the inner door trim pad.
2. Withdraw the stowage bin.
1. Disconnect the battery negative lead.
2. Remove the four cross-head screws securing
the glove box liner to the glove box and
withdraw the liner.
3. Disconnect the electrical leads to the rear
passenger cigar lighter.
4. Maneuver the switch panel through the panel
opening and place inside the glove box.
NOTE: To enable the glove box/ console
assembly to be removed, disconnect the
parking, brake cable from the parking brake
lever, to allow the lever to be raised to its
uppermost position.
5. Unscrew and remove the transfer gear knob.
Refitting
--
\
3. Reverse the removal procedure.
NOTE: R e f e r t o S e c t i o n 8 6 ElectricalAutomatic gear selector ilhrmination panel,
for full instructions on dismantling the
main gear selector knob and illumination
panel.
6. Remove the main gear selector knob.
7. Carefully pry the outer inset panel out of the
disconnect the
floor
console,
mounted
electrical multi-plug to the inset graphics
panel, withdraw the assembly off the main
gearbox selector.
8. Remove the two bolts (with plain and spring
washers) and ‘two screws (with plain washers)
securing the floor-mounted console to the
gearbox tunnel.
.
.‘\
i
40
.
REVISED: APR. 67
. .._
...’
CHASSIS AND BODY
76
LOWER DASH PANEL
Remove and refit
Removing
,': I'
9. Ease the assembly rear-wards to detach the
small location tab at the front of the console
from the bottom of the radio housing.
IO. Maneuver the assembly from the parking brake
and gear levers and remove it from the
vehicle.
1. Disconnect the battery negative lead.
2. Pry the louvre from the dash.
3. Remove the two cross-head screws from the
bottom of the panel located above the pedals.
4. Remove the single cross-head screw from the
side of the panel adjacent to the front door
courtesy light switch.
5. Remove the two cross-head screws from the
top of the louvre opening.
6. Remove the single cross-head screw above the
rheostat switch.
Refitting
11. Reverse the removal procedure ensuring that
all electrical plugs are fitted securely and
correctly. Arrange the electrical wiring beneath
the console to ensure it does not become
trapped between any joint faces.
1
7. Lower the dash panel and disconnect the
electrical plug at the rear of the rheostat
switch and detach the bulb check unit from
the spring clip.
8. Remove the panel from the vehicle.
Refitting
9. Reverse the removal procedure.
::
76
l-l
..
1987 RANGE
ROVER
CHASSIS AND BODY
‘. .‘.
.a
::.
RADIO HOUSING
CENTRE DASH PANEL
Remove and refit
Remove and refit
Removing
Removing
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.‘.
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1. Disconnect the battery negative lead.
2. Remove the glove box and floor-mounted
console assembly.
3. Remove the radio from the housing (See
Manufacturers instructions for removal and
installation).
4. Pry the differential lock warning lamp out of
the radio console and disconnect the electrical
leads.
5. Remove the single screw securing the housing
to the gearbox tunnel.
6. Tilt the front of the housing upwards and
maneuver it away from the centre dash unit as
far as the cigar lighter electrical leads will
permit.
7. Disconnect the leads from the rear of the cigar
lighter and remove radio housing complete
with lighter unit.
1. Disconnect the battery negative lead.
2. Remove the lower dash panel to give access
to the single screw securing the side of the
centre dash and release the screw.
3. Remove the glove box and floor-mounted
console assembly.
4. Remove the radio and radio housing.
5. Detach the fuse box cover and remove the
three screws securing the main and auxiliary
fuse box body to the dash.
6. Pull the five heater control knobs off their
levers.
7. Remove the two screws at the top of the
heater graphics panel. Pull the panel away
from the dash and remove the illumination
bulbs from their locations.
8. Withdraw the graphics panel.
9. Pry the auxiliary switch panel away from the
dash.
switch multi-plug to aid
10. Identify each
reassembly, and disconnect them from the
switches.
11. Release the three screws securing the top of
the centre dash to the louvre dash panel.
12. Remove the two screws securing the side of
the centre dash unit (front passenger side).
\
.’
:
,
.
Refitting
:
8. Reverse the removal procedure ensuring the
radio electrical leads do not bl-come trapped
when refitting the radio to the housing.
13. Maneuver the centre dash away from the
louvre dash and remove it from the vehicle.
, ..:>
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..‘.
‘.
42
.
.
'
;g$; 1 9 8 7
Refitting
Reverse the removal procedure ensuring that
all electrical multi-plugs are fitted correctly and
secure in their respective switches.
Arrange all electrical wiring and harnesses so
that they do not become trapped between
any mating faces.
CHASSIS AND BODY
LOUVRE DASH PANEL
Remove and refit
Removing
1. Disconnect the battery negative lead.
2. Carefully pry the clock out of the dash,
disconnect the electrical leads and remove the
bulb and holder from its location.
3. Remove the single screw securing the end of
the dash panel located adjacent to the
passenger courtesy light switch.
4. Carefully pry the four louvres out of their
openings to gain access to the eight screws
securing the louvre panel to the dashboard.
5. Carefully pry the exterior mirror control switch
out of the louvre panel and disconnect the
electrical multi-plugs, remove the remaining
screw at the top of the exterior driving mirror
control panel opening.
6. Remove the three screws securing the bottom
of the panel to the centre dash panel. Remove
the remaining three screws above the blower
motor trim panel.
7. Withdraw the louvre panel from the vehicle.
Refitting
8. Reverse the removal procedure.
43
CHASSIS AND BODY
DASHBOARD
Remove and refit
Removing
Service tools:
18G1014 - Extractor for steering wheel
18G1014.2 - Adaptor pins
1. Disconnect the battery negative lead.
2. Using service tool 18G1014 and 18G1014-2
remove the steering wheel, secure the cruise
control cassette in position with adhesive tape.
3. Remove the lower dash panel from below the
steering column.
4. Remove the instrument binnacle (refer to
instrument binnacle remove and refit in
Section 86-Electrical).
5. Remove the glove box console assembiy.
6. Remove the radio housing.
7. Remove the centre dash panel.
1987 RANGE
ROVER
8. Detach the dashboard evaporator assembly,
do not evacuate the air conditioning assembly,
with refrigerant hoses still attached ease the
assembly away from the bulkhead and lay on
the gearbox tunnel/passenger footwell area.
(Refer to Section 82 - Air Conditioning for the
removal of the dashboard assembly).
9. Remove the three nuts with washers retaining
the front passenger grab handle, accessible
from under the dashboard and withdraw the
grab handle.
10. Remove the five nuts with washers retaining
the map tray base plate, accessible from under
the dashboard and withdraw the base plate
from the inset in the dashboard.
11. Disconnect the side and centre air vent hoses
from the heater unit.
12. Maneuver the dashboard and withdraw it from
the vehicle.
,
.
‘.’
,,.‘.,’
ro;;; 1987
CHASSIS AND BODY ri%ii
.I’
Refitting
FRONT SPOILER
CAUTION: When refitting the dash components
ensure that all electrical leads are arranged in
such a manner as to prevent them becoming
trapped between any of the dash mating faces.
The spoiler will reduce the vehicle approach angle
by approximately 10”. W h e r e t h e v e h i c l e i s
expected to perform on rough or hilly terrain, it is
advisable to remove the spoiler to prevent any
damage which may occur due to ground contact.
,,”
!
”
13. Reverse the removal procedure ensuring that
the dashboard locates on three brackets below
the windscreen inner sealing rubber.
14. Ease the sealing rubber over the top of the
dashboard.
The spoiler may be removed as follows:
1. Disconnect the electrical connections at the
rear of both auxiliary driving lamps, accessible
through the front wheel arches.
2. Remove the two screws (with spring washers)
securing the centre of the spoiler.
3. Remove the four nuts (with spring washers)
located behind the front bumper above the
driving lamp pockets, accessible from beneath
the vehicle.
4. Remove the two bolts, nuts and washers
securing the outer edges of the spoiler to the
corners of the front fenders, located forward
of the front road wheels.
5. Remove the spoiler complete with driving
lamps.
-
-’
-7
Refitting
6. Reverse the removal instructions.
REVISED: SEPT. 87
45
.:
1987 KANCik
ROVER
CHASSIS AND BODY
ELECT’RICALLY OPERATED SUNSHINE ROOF
17
\
SUNROOF ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
4
Roof panel
Sunroof headliner
Insulation pad
Roof seals (front and rear)
Sunroof headliner retaining clips (quantity - 6)
Roof panel retaining screws (quantity - 6)
Water channel
Water channel connectors
Support bracket-water channel
Slide shoe-water channel
Motor bracket/guide tube assembly
Operating motor
6
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Motor retaining screws
Relay
tower guide rails
Front guide rails
Slide mechanism
Rear guide
Pivot bracket
Slide shoe
Rear edge trim finisher
Wind deflector assembly
Wind deflector operating arms
Support bracket (quantity - 6)
ADDITION: SEPT. 87
;rv;; 1 9 8 7
CHASSIS AND BODY
OPERATING MOTOR, MICRO-SWITCH AND
RELAY
OPERATION
The sunroof operates in a tilt and slide action
controlled by the rocker switch adjacent to the
interior roof lamp, with ignition switched ‘ON’.
’
1. Depress front of switch to lift rear edge of
sunroof into ‘Tilt’ position.
2. Depress rear edge of switch to close roof.
3. Depress rear of switch to slide sunroof into
‘Open’ position.
4. Depress front of switch to slide sunroof into
‘Close’ position.
NOTE: The electric drive cuts out automatically
in the closed, tilt and open positions. If the
switch is operated in the wrong direction in one
of these positions, press the switch once to reset
and again to operate roof.
EMERGENCY OPERATION
if the sun roof fails to operate, check the fuse and
renew if necessary. To close the roof in the event
of electrical failure c a r r y o u t t h e f o l l o w i n g
procedure.
NOTE: The motor drive spindle retaining nut is
factory set to the correct torque value. If the
roof fails to operate, and drive failure is
suspected, check the retaining nut torque and
retighten to the correct value - 37 to 44 in lb
(4.15 to 5.00 Nm).
Remove and refit
Removing
1. Ensure sunroof is fully closed. Disconnect the
battery negative lead.
2. Remove interior lamp mounting panel by
loosening two turnbuckles to gain access to
the motor.
3. Disconnect two wiring connectors.
4. Remove three securing screws and withdraw
motor.
5. Remove securing screw and withdraw relay.
6. Remove micro-switch from motor by drilling
out securing rivets, if required.
Refitting
I.
,
‘.Z. .
Lower the interior lamp mounting panel by
releasing two turnbuckles.
2. Remove the emergency handle from the
vehicle tool kit.
3. Engage handle in motor drive spindle and turn
to close roof.
MAINTENANCE
At each service blow drain tubes out to ensure they
are not blocked or kinked. Blow upwards to clear
rear drain tubes which are clipped to the rear mud
flap supports. Blow downwards to clear front drain
tubes which run down each ‘A’ post and exit at
back of engine bay.
Annually: Clean sunroof opening thoroughly.
Note: W h e r e t h e v e h i c l e is operated in
extremely dusty conditions more frequent
cleaning is recommended.
7. Secure new micro-switch using suitable nuts
and bolts to replace rivets. Tighten nuts and
apply a spot of paint to threads.
8. Ensure motor is in the ‘park’ position, i.e. hole
on driven gear aligned with drive spindle.
9. Reverse removal procedure.
10. Check operation of su.nroof in all positions.
ROOF PANEL SEALS
Remove and refit
Removing
I.
Position sunroof in the tilt position and
disconnect battery negative terminal.
3. Unclip sunroof headliner from roof panel front
and slide the sunroof headliner back fully.
3. Remove three roof panel fixing screws from
each side and remove panel.
4. Place the roof panel on a suitable surface to
avoid damage, and remove both seals.
Continued
ADDITION: SEPT. 87/REVISED: DEC. 87
4
7
1987 KANGt
ROVER
CHASSIS AND BODY
Refitting
5.26
Position front seal to front edge of panel,
ensuring that there is an equal length of seal
each side of the centre point. Secure seal
using a rubber mallet.
Position the rear seal on one side immediately
to rear of the front seal. Secure seal around
panel edge ensuring a good fit around
corners. Trim off excess seal at joint with front
seal using suitable snips, ensuring that the
joint is closed.
Refit the roof panel.
6,22
?A?
:.--;
SUNROOF ASSEMBLY
Remove and refit
- including roof panel, sliding mechanism, wind
deflector,-motor- mounting bracket and guide
tubes.
Removing
NOTE: lower vehicle headlining O N L Y i f
removing motor mounting bracket and guide
tubes. Note that the headlining is secured
around the roof opening using an adhesive tape.
Remove edge trim and eight edge clips, carefully
peel back headlining to remove.
1. Partially open sunroof rearwards and carefully
unclip sunroof headliner from roof panel front.
Slide the sunroof headliner back fully.
2. P o s i t i o n s u n r o o f i n t h e t i l t p o s i t i o n a n d
disconnect battery negative terminal.
3. Remove three roof panel fixing screws from
each side and remove panel.
4. Remove motor securing screws and withdraw
motor.
5. Remove the guide rail screws, seven each side.
6. Remove the pivot bracket and remove front
guide rail.
”
.’
7. Remove the slide and tilt mechanism complete
with flexible drive cable from both sides. Do
not strip these assemblies unless replacement
parts are required.
[email protected]
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48
ADDITION: SEPT. 87/REVISED: DEC. 87
--===G
Continued
po;f; 1 9 8 7
CHASSIS AND BODY
8. Unclip both wind deflector operating arms
from rear mounting brackets. Remove arms
from deflector, if required.
:
Refitting
NOTE: During assembly lightly lubricate all
sliding parts using a silicon spray.
13. Position motor b r a c k e t a n d g u i d e t u b e
assembly. Fit and tighten the securing screws.
14. Position right hand guide rail in rear retaining
bracket, push reanvards fully and locate
leading edge under drive cable opening.
Repeat operation for left hand guide rail.
15. Align fixing holes, and loosely fit screw in
seventh hole from the front.
16. Position finisher to rear edge of sun roof
opening and secure using seven screws.
17. Position sunroof headliner assembly into outer
guide runners, and push fully rearwards.
18. Lightly lubricate drive cables. Ensure that the
slide and tilt mechanism is fully assembled.
19. Push the cable fully into the right hand side
guide tube. Loop remaining cable and enter
the rear end into the right hand inner side
runner.
20. Repeat operation 19. for left hand side. Push
both assemblies rear-wards to take up slack in
the cables, and push a further 75 mm (3 in) to
the rear.
21. Position both front guide rails, aligning with
the four forward holes. Secure with screws, do
not tighten.
22. Position both pivot brackets, fit but do not
tighten fixing screws.
23. Fit the wind deflector and fully tighten fixings.
24. Position right hand operating arm in locating
slot in deflector. Secure opposite end in frame
bracket. Repeat for left hand side.
RR2208E
9. Remove seven fixing screws, and withdraw
wind deflector.
10. Remove lower guide rails and rear edge
finisher, seven screws, if required.
11. Remove fixing screws from guide tubes, two
each side. Remove five fixing screws and
withdraw motor mounting bracket.
12. Pull sunroof headliner assembly forward and
remove.
Continued
,‘-
ADDITION: SEPT. 87
49
1987 RANGt
ROVER
‘.
CHASSIS AND BODY
25. Pull right hand slide and tilt mechanism
forward, align with pivot bracket and secure in
position using setting key. Repeat operation
for left hand side.
RR2297E
/’ 6 ’
RR2327E
‘.
26. Tighten screws to guide rails, seven each side.
27. Fit and secure relay.
28. Ensure operating motor is in the park position
i.e. hole on driven gear aligned with drive
spindle. Fit and secure to mounting bracket.
29. Remove setting keys. Temporarily connect
wiring
reconnect
and
switch
operating
including battery.
30. Operate switch sequence to ‘tilt’ position.
31. Position roof panel into roof opening and
secure with six fixing screws, do not tighten.
32. Put roof into ‘closed’ position and adjust roof
profile. The panel profile should be 0.5 mm
low at forward edge, 1 mm high at rear edge.
33. Tighten roof panel screws.
34. Tilt sunroof, pull sunroof headliner forward
and locate rear brackets in tilt mechanism.
Align front six clips and push to secure.
35. Check operation of sunroof in all operating
modes.
50
36. Refit vehicle headlining. The headlining is
secured around the sunroof opening with ‘3M’
adhesive tape.
37. Refit the eight edge clips as shown.
38. Finally fit the edging finisher.
ADDITION: SEPT. 87
PO;;:
1987
CHASSIS AND BODY
4. Secure connecting a r m s t o f r a m e u s i n g
suitable rivets before retrimming frame.
5. Retrim frame using a new headliner cover.
inset shows section through frame indicating
where adhesive is applied. Dimension ‘A’
should be radially constant.
SUNROOF HEADLINER ASSEMBLY
Remove, retrim and refit
Removing and retrimming
sunroof headliner assembly as
1. Remove
detailed in Sunroof Assembly - remove and
refit.
2. Remove trim covering from frame assembly.
Note that it is not normally necessary to
remove the three pads and insulation pad
shown in illustration.
channel by
3. If required:
remove
water
unclipping connecting arms. Drill out rivets
securing connecting arms to frame.
Refitting
sunroof
headliner
6. Refit
reassemble sunroof.
Continued
ADDITION: SEPT. 87 / REVISED: MARCH 90
assembly
and
KANGli
lg8’ R O V E R
CHASSIS AND B O D Y
HEADLINING - 1987 MODEL YEAR IMPROVEMENT
- \
Remove and refit
Removing
1. Remove spare wheel from the vehicle.
2. Remove the rear seat belt upper guide
brackets and inertia reel assemblies.
3. Fold the rear seat backrest forward and recline
the front seats as far as possible.
4. Disconnect the battery negative lead.
5. Remove the two roof lamp assemblies. (Lower
and remove the interior lamp mounting panel
if the vehicle has a sunroof)
6. Remove the rear view mirror and mounting
bracket.
7. Remove the two sun visors and centre
retaining bracket.
8. Remove the front and rear passenger grab
handles. Sunroof vehicles: Remove edge trim
and eight edge clips from roof opening, and
carefully peel back headlining to remove.
9. M’ith assistance support the front of the
headlining, while removing the two plastic
retaining clips above the rear quarter light
glass.
10. While the headlining is still being supported,
remove the two plastic retaining clips securing
the rear end of the headlining, located
adjacent to the upper tailgate hinges.
11. Pull the headlining forward to clear the rear
quarter trim. Lower the headlining and
disconnect the electrical leads from the roof
mounted speakers.
12. Remove the headlining through the tailgate.
CAUTION: T o a s s i s t r e m o v a l t i l t t h e
headlining at an angle. DO NOT flex the
headlining as damage may occur.
Refitting
8. Reverse the removal procedure. Sunroof
vehicles: The headlining is secured around the
roof opening with ‘3M’ adhesive tape. Refit
the eight edge clips and fit the edging finisher.
See also Sunroof assembly, remove and refit.
!
,_..- .,.
j
:. .’
52
.
ADDITION: SEPT. 87 / REVISED: MARCH 90
FRONT DOOR - TRIM PANEL
5. Remove the two finisher buttons from the
bottom of the door pull pocket to reveal the
securing screws.
6. Remove the screws and withdraw the pocket
from the trim panel.
Remove and refit
Removing
1. Disconnect the battery negative terminal.
2. R e m o v e t h e s c r e w s e c u r i n g t h e h a n d l e
surround.
3. Remove the surround.
I
!
I
\
RR23ki4E
’
7. Using a taped screwdriver, carefully pry the
trim panel away from the door.
NOTE: Support the trim panel while the
speaker leads are disconnected.
4. Carefully pry the sill locking button surround
from the trim panel.
8.
If necessary the stowage bin front panel can
be removed by releasing the screws at the rear
of the trim panel.
Refitting
9. Reverse the removal procedure.
Continued
ADDITION: SEPT. 88
5
3
:.
76
RANGE
lg8’ R O V E R
BODY
FRONT DOOR LOCK, OUTSIDE AND INSIDE
DOOR RELEASE HANDLES
Remove and refit
Removing
1. Remove the interior door release handle bezel
and sill locking button bezel.
2. Remove the two screws from the bottom of
the door pull pocket remove the pocket and
prise the door trim panel from the door.
Disconnect the electrical leads to the door
speaker and remove the plastic vapor barrier
sheet.
Remove the window lift motor. (Refer to the
electrical section in main Workshop Manual).
4. Remove the door glass and regulator. (Refer to
door glass and regulator remove and refit in
main Workshop Manual).
5. Remove the door lock actuator. (Refer to
electrical section in main Workshop Manual).
6. Disconnect the control rod from the key
operated lock by releasing the metal clip at
the bottom of the rod.
7. Disconnect the control rod from the outside
door release handle by pulling it out of the
plastic ferrule.
connector
rod
control
the
8. Disconnect
between the inside door release handle and
the door lock by releasing the metal clip and
pulling one of the control rods out of the
plastic connecting block. This is accessible
through the small centre cut - out in the door
panel. (The control rod also passes through a
guide bracket on the inside of the inner door
panel).
9. From inside the door panel push out the small
pin which secures the quadrant to the inner
door panel. Push the quadrant out of the
panel.
10. Remove the two screws securing the sill
locking button to the door. manouver the sill
button and remove it from the control rod.
11. Release the door lock by removing the two
countersunk screws from the door edge and
the single screw with shakeproof washer on
the inner door panel.
,
5
4
ADDITION: SEPT. 88
8, . .
12. Withdraw the lock through the lower rear cut out on the inner door panel.
NOTE: If necessary the following items can
be removed.
13. Remove the two nuts (with shakeproof
washers) and retaining bracket securing the
outside release handle to the outer door
panel, accessible through the upper rear cut out on the inner door panel.
14. Carefully detach the door release handle from
the outer door panel.
15. Remove the two screws securing the inside
door release handle to the inner door panel.
16. Withdraw the handle from its location with
half of the connecting rod attached.
3. Disconnect the heaters electrical wiring at the
multiplug.
4. Remove heater retaining bracket screw.
5. Remove T? clip and colored cam link from
end of barrel assembly.
Caution: Ensure the loose barrel assembly
remains in position, to avoid components falling
apart.
6. Remove heater retaining bracket, complete
with de-icing element, switch and wiring
assembly.
Refit
7. Hold de-icing element in positiori and fit
heater retaining bracket assembly.
8. Reverse removal instructions 1 to 5.
9. Recode the radio.
Refitting
17. Reverse the removal procedure items 1 to 16.
NOTE: When refitting the door glass frame,
ensure that it is positioned to suit the door
opening before fully tightening the frame
securing bolts.
HEATED FRONT DOOR LOCK ASSEMBLY - 1991
MODEL YEAR
Remove and refit
ADjUSTMENT - F R O N T D O O R L O C K A N D
HANDLE ASSEMBLY
Inside door release handle to lock
1. Refit the inside door release handle bezel
before any adjustment is made, allowing the
handle to be set for the correct operating
position.
2. Rotate the spring tensioned nyloc nut at the
door lock clockwise or counter - clockwise to
shorten or extend the operating length of the
rod as required.
Remove
1. Disconnect battery negative lead.
2. Remove outside front door handle assembly.
RR230 1 E
ADDITION: SEPT. 88 / REVISED: SEPT. 90
5
5
1989-91 KANGE
KOVEK
Outside door release handle to lock
3. Disconnect the connecting rod at the rear of
the outer door release handle by releasing the
the rod from the plastic ferrule, rotate the rod
clockwise or counter - clockwise to shorten or
extend the operating length, refit the rod to
the ferrule.
NOTE: Door release should occur before
the total handle movement is made to
provide a small overthrow movement.
5. Remove the two finisher buttons from the
bottom of the door pull pocket to reveal the
securing screws.
Remove the screws and withdraw the pocket
from the trim panel.
Using a taped screwdriver, carefully pry the
trim panel away from the door.
Disconnect the electrical plug from the
window lift switch.
Remove the window lift switch by pushing
from behind the trim panel.
.
5
REAR DOOR - TRIM PANEL
Remove and refit
Removing
1. Disconnect the battery negative terminal.
2. R e m o v e t h e s c r e w s e c u r i n g t h e h a n d l e
surround.
3. Remove the surround.
Refitting
10. Reverse the removal instructions.
.
RR2476
4. Pry the door locking button surround from the
trim panel.
.’
5
6
ADDITION: SEPT. 88 I REVISED: SEPT. 90
!
:’
.L,..(
,’ .
REAR DOOR LOCK, OUTSIDE AND INSIDE DOOR
RELEASE HANDLES
Remove and refit
Removing
7. Ensure the window is fully closed position and
8. Release the door lock by removing the two
countersunk screws from the door edge and
the single screw (with shakeproof washer) on
the inside of the door. Retrieve any spacing
washers which may be fitted between the
inner door panel and lock.
9. Withdraw the lock through the upper rear
opening in the inner door panel.
disconnect the battery negative terminal.
2. Remove the interior door handle surround, pry
3.
4.
5.
6.
7.
the window lift switch from the trim panel and
disconnect the electrical multi - plug.
Pry the sill button from the trim panel.
Remove the two screws from the bottom of
the door pull pocket accessible after removing
the two buttons and detach the trim panel
from the door panel. Remove the plastic vapor
barrier sheet.
Disconnect the control rod from the inside
door release handle by pulling the rod out of
its location at the door lock.
Disconnect the sill locking control rod from
the door lock by releasing the metal clip.
Disconnect the control rod from the outside
door release handle by pulling it out of the
plastic ferrule.
NOTE: If necessary the following items can
also be removed.
70. Remove
the two nuts (with shakeproof
washers) and retaining bracket securing the
o u t s i d e d o o r release handle which are
accessible through the upper rear cut - out on
the inner door panel.
71. Carefully detach the outside door release
handle from the outer door panel.
72. Remove the two screws (with plain washers)
securing the inside door release handle to the
inner door panel.
13. Withdraw the handle from its location with the
connecting rod attached.
Continued
I
i
ADDITION: SEPT. 88
57
‘. _
1989 RANCE
ROVER
14. Remove the two screws securing the sill
locking button to the inner door panel and
detach the sill button from the bellcrank.
ADjUSTMENT - REAR DOOR LOCK AND HANDLE
ASSEMBLY - 4 Door models
Outside door release handle to lock
Sill locking bellcranks
15. Using a small screwdriver, or 3.175 mm (0.125
in) diameter rod, press the plastic locking pins
through the respective square inserts in the
inner door panel, until they can be retrieved
from inside the door.
16. Release the bellcranks from the inner door
panel and unhook the respective connecting
rods.
17. Withdraw the bellcranks from the inner door
panel.
1. Disconnect the short offset connecting rod at
the rear of the door outer release handle,
rotate the rod clockwise or counter clockwise to shorten or extend the operating
length of the rod as required.
NOTE: Door release should occur before
the total handle movement is made to
provide a small overthrow movement.
.
NOTE: When refitting the bellcranks the
locking pins are entered into the square
insert from outside and pressed in flush.
Refitting
18. Reverse the removal procedure items 1 to 17.
NOTE: When refitting the door glass frame,
ensure that it is positioned to suit the door
opening before fully tightening the frame
securing bolts.
I
5
8
ADDITION: SEPT. 88
:.
.,+x..
ASYMMETRIC SPLIT REAR SEAT - LOCKING
MECHANISM
Refitting
NOTE: 1989 Model Year vehicles have a revised
seat locking mechanism which incorporates a
push button release in place of a finger lift
button. The revised latch and striker give the
seat an improved positive location.
13. Refitting is a reversal of the removal procedure
noting that when the seat release button is
screwed onto the operating rod there must be
a gap of 5 - 8 mm (0.196 - 0.312 inch)
between the head of the button and lip of the
trim covering after the button has been
depressed.
Remove and refit
Removing
1. Depress the seat release button and fold the
.,.
seat back forward.
2. Unscrew and remove the seat release button.
3. Pry out the two trim buttons securing the trim
covering to the latch tower.
4. Manouver the trim covering from the tower.
5. Remove the three screws securing the latch to
the tower, noting that access to the single
screw is gained through the hole in the front
of the tower.
6. Retrieve the latch from the opening at the rear
of the tower. If necessary retrieve the single
screw.
7. The operating rod can be removed from the
latch by releasing the rod at the plastic clip.
Continued
RR24OlE
ADDITION: SEPT. 88
59
RANGE
lg8’ ROVER
ENGINE UNDERTRAY
Removal of engine under-tray fitted to 1989 model
year vehicles is necessary when changing the oil
filter. Remove will also facilitate attention to engine,
cooling system and steering components.
Remove and refit
1. Disconnect battery negative lead.
2. Remove three screws, securing under-tray to
spoiler.
3. Remove two screws, one each side, securing
rear of under-tray to chassis mounting brackets.
4. Remove under-tray by carefully flexing to clear
rear mountings.
5. Removal of one or both rear mounting
brackets may be necessary, for example, when
removing steering box. Remove the nut and
washer from the chassis bolt.
6. Withdraw the undertray mounting bracket.
Refitting
7. Reverse the removal procedure.
‘\
I
I
.;.
.I
”
..T’
:y,.
60
.
ADDITION: SEPT. 88
PO:;; 1989
CHASSIS AND BODY r-l
76
FRONT DOOR
Adjusting
Remove, refit and adjust.
Removing
1. Disconnect the battery negative lead.
2. Open the door to be removed.
3. Remove the trim panel from side of footwell
by carefully levering under the trim and prising
out the two plastic clips.
:.
12. Adjust the door by means of shims between
the hinge and door to move the door forward
or rearward in the opening.
13. L o o s e n t h e s i x T o r x s c r e w s s e c u r i n g t h e
hinges to the door to adjust the door up and
down or in and out of the opening. Retighten
the screws to the specified torque values.
14. The door lock striker can be adjusted by
loosening the striker and moving it in the
appropriate
direction or
adding
and
subtracting spacing washers between the
striker and ‘8’ post.
\ !
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1
RR 1588M
15. Note: If it is necessary to remove hinges from
‘A’ post they should be refitted in exactly the
same position using the same thickness of
shims.
RR2685M
4. Locate and disconnect all door wiring plugs.
5. Disengage the grommets either side of ‘A’
post and feed wiring out.
6. Drive out the roll pin from the door check
link.
7. Remove ‘C’ clips from grooves in hinge pins.
WARNING: Instruction 8. MUST BE carried
out with assistance.
8. Carefully lift the opened door off the hinge
pins.
REAR PASSENGER DOOR
Remove, refit and adjust.
Removing
1. Disconnect the battery negative lead.
2. Remove wiring grommet from the ‘B’ post.
3. Withdraw the door wiring plugs from the ‘B’
post and disconnect them.
4. Remove the two bolts securing the check
strap to ‘B’ post.
Refitting
9. Reverse the removal procedure. Renew the’C’
clips if worn or distorted.
10. With door fully open reconnect wiring plugs
ensuring they are located above the trim
panel.
11. Check the operation of the door and lock. If
necessary, adjust the door and striker plate.
ADDITION: MAY 89REVISED: SEPT. 89
61
RANGE
ls8’ ROVER
76 CHASSIS AND BODY
l-l
5. Remove ‘C’ clips from grooves in the hinge
pins.
COWL PANEL
Remove and Refit
WARNING: Instruction 6. MUST BE carried
out with assistance.
6. Carefully lift the opened door off the hinge
pins.
I
Removing
1. Disconnect the battery negative lead and
remove the hood.
2. Remove the wiper arms and two nuts securing
the wheel boxes to the cowl panel and
remove the two sealing rubbers.
3. Remove the two cross-head screws retaining
the panel to the ‘A’ post mounting brackets
located above the front door hinges.
!
i;
5
RR2683M
\Y
Irll
hh
Refitting
7. Reverse the removal procedure. Renew ‘C’
clips if worn or distorted.
8. Check the operation of the door and lock. If
necessary, adjust the door and striker plate.
4. Remove the nine cross-head screws securing
the front of the cowl panel.
5. Remove the four bolts with spring and plain
washers securing cowl panel to front fenders
accessible from the front of the cowl panel.
Adjusting
9. Adjust the door by means of shims between
the hinge and door to move the door forward
or rearward in the opening.
10. Loosen the six Torx screws securing the
hinges to the door to adjust the door up and
down or in and out of the opening. Retighten
the screws to the specified torque values.
11. Adjustment to the door striker is identical to
front doors.
12. Note: If it is necessary to remove hinges from
‘B’ post they should be refitted in exactly the
same position using the same thickness of
shims.
62
ADDITION: MAY 89lREVISED: SEPT. 89
;“d”z; 1989
CHASSIS AND BODY
6. With assistance place a tube over each of the
hinges and lower to enable the cowl panel to
be fed over the hinges, gradually return the
hinges to their upright position.
SILL FINISHER
Remove and refit
Remove
WARNING: Gradually let the torsion bar
s p r i n g t e n s i o n r e t u r n t h e h i n g e s IO t h e i r
upright position to prevent the possibility
of personal injury or damage to the vehicle.
Refitting
I. Remove nut and washer from underneath the
front of sill finisher.
2. Using a drift tap through the centre piece of
the ten ‘Recut’ fixing rivets.
3. Carefully pry out the Recut rivets and remove
the sill finisher.
7. Reverse the cowl panel removal instruction.
8. Using a soft blunt implement ease the
windscreen rubber up onto the top of the
cowl panel.
FRONT WHEEL ARCH LINER
Remove and refit
Refit
4. Reverse the removal procedure, renewing the
Recut rivets and ensuring the metal tube insert
is refitted into the sill finisher where the bolt
goes through.
Remove
1. Remove the bolt and washer securing the rear
lower edge of the liner.
2. Carefully pry out the centre studs of the eight
plastic clips spaced around the liner.
3. Carefully pry out the plastic clips.
4. Remove the liner.
Refit
5. Reverse the removal procedure renew the
clips as necessary.
ADDITION: MAY 89/REVISED: MARCH 90
6
3
1 9 9 0 RANGE
ROVER
CHASSIS AND B O D Y
a
a
I
f
P
II
ww
8
1
i1~
3
s
ADDITION: SEPT. 99
I
CHASSIS AND BODY
CHASSIS FRAME - 1990 Model Year
I
‘_
Alignment check - RR2718E
millimeters
Diagram reference
BB
cc
DD
EE
FF
Centre line of front axle
Centre line of rear axle
Frame datum line
Side member datum line
Datum line
2
3
4
5
6
7
8
9
10
11
12
13A
138
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Frame datum to underside of cross-member
Reference dimension
To face of boss (both sides)
Check figure
Reference dimension
Reference dimension
100.0
2540,OO
AA Wheelbase reference dimension
264,525
150,80
266,70
237.74
327.81
979,94
2179,73
291,74
707,96
1468,49
1025,27
338,84
222.25
252,904
024,92
935,43
838,2
630.94
344,17
485,77
405.77
028,68
129.03
2479.45
1290,34
1657,04
2598,44
79,09
465‘48
1398,88
368,30
317,50
635,00
ADDITION: SEPT. 89
inches
2 I,27
+ 2.54
_?I I,27
2 2.54
f
+
+
+
t
+
&
+
2,54
2,54
1,54
2.54
2,54
2,54
2.54
2.54
+
+
+
+
+
+
+
_f
+
+
+
+
+
+
++-
2,54
0,38
I,27
I,27
2,54
2,54
0,38
2,54
0,25
0,38
0,38
0,38
0,38
2,54
0,38
2,54
10.400
5.937
10.500
9.360
12.906
38.58
85.816
11.486
27.872
57.815
40.36
13.34
8.750
9.960
32.477
36.828
33.000
24.840
13.550
19.125
19.125
32.625
5.080
97.616
50.800
65.238
102.301
3.114
18.326
55.074
14.50
12.50
25.00
+ .050
+ .I00
+ .050
+ .I00
-f
r.
+
f+
+
+
2
.I00
,100
.I00
,100
.I00
.I00
.I00
.I00
+
+
+
+
2
+
+
+
+
-f.
k
+
+
+
+
+
.lOO
.015
.050
.050
.lOO
.lOO
.015
.I00
.OlO
.015
.015
.015
.015
.lOO
.015
.I00
65
,,
CHASSIS FRAME
Diagram reference
.-.
millimeters
inches
I
SECTION W - W
33 Frame datum line DD
34
35
155.91 + 1,27
990,6 k 0,38
6.14 2 .050
39.00 + .015
488,95 + 2.54
295.27 + 2,54
19.250 + .lOO
11.625 + .I00
660,40 + 0,25
80,39 + I,27
26.00 2 .'OlO
3.187 + .050
80.39 + I,27
660,40 + 0.25
9.53 +. 2,54
3.165 + .050
26.000 + .OlO
0.375 + .I00
SECTION X - X
36 Frame datum line DD
37
38
SECTION Y - Y
.’
98 Frame datum line DD
40
41
SECTION 2 - Z
42 Frame datum line DD
43
44
45
‘,‘. .’
.’
.,
I.:,,
”
,..’
.:
‘.
:
.’
;--.
2’
!
ADDITION: SEPT. 89
,,:.
CHASSIS AND B O D Y
GLASS SUNROOF 1991 MODEL YEAR
Operation
The sunroof operates in a tilt and slide action
controlled by a rocker switch near the interior lamp.
A drive motor and control unit is located behind
the switch and interior lamp panel. The control
units function is to stop the drive motor at the full
tilt and slide positions.
The removal and refit of the sunroof assemblies
shown can be carried out without removing the
complete sunroof assembly.
SUNROOF WIND DEFLECTOR ASSEMBLY
Remove, refit and adjust
Remove
1. Open sunroof.
2. Remove the two screws accessed through the
slot in the deflector
3. Remove the wind deflector assembly
GLASS SUNROOF ASSEMBLY.
Remove refit and adjust
‘. ,,.I..
8. Check the height of the sunroof panel against
the roof aperture. The trimmed edge of the
glass sunroof should stand approximately lmm
proud of the roof aperture.
9. Adjust by releasing the four screws and
moving the sunroof up or down as required.
Tighten the screws.
10. Fit the two mechanism covers.
11. Fully check the sunroof operates correctly.
Remove
1. Open the sunroof to the tilt position.
2. Remove the two mechanism covers. Slide
rearwards to disengage from their location and
lift out.
3. Remove two screws from each side as shown.
4. Remove glass sunroof.
Refit
4. Replace the wind deflector assembly
5. Fit the two screws firmly but do not tighten.
Adjust
attachment of
and
Adjustment
Note:
deflector is by the same two screws.
Refit and adjust
5. Replace the glass sunroof
6. Fit the lour screws firmly but do not tighten.
7. Close the sunroof
the
6. Adjust the wind deflector rearwards or
fonvards into the position shown. At the same
time adjust the height A’ to 20mm by moving
the slotted metal strip rearwards or forwards.
Tighten the two screws.
7. Ensure the deflector does not catch the front
edge of the roof aperture when operated.
8. On completion fully check that the sunroof
operates correctly.
ADDITION: SEPT. 90
67
RANGE
lgg’ R O V E R
Manual operation.
If the sunroof fails to operate by electrical
means the sunroof can be opened or closed
manually with the key provided.
Remove the two tumbuckles to access the
sunroof motor spindle located behind the
switch plate.
Engage the key into the motor spindle and
turn to open or close the sunroof panel.
On completion of manual operation the motor
spindle MUST BE TURNED BACK HALF A
TURN TO ENSURE ENGAGEMENT TO THE
ELECTRICAL DRIVE MOTOR.
4. Release the front of the headlining sufficiently
to access the motor drive assembly and
control unit.
5. Disconnect the two multiplugs from the
control unit to the motor drive unit and to the
main harness.
Remove the three screws securing the motor
drive assembly.
Remove the motor drive assembly.
To remove the control unit undo the fixing
screw. Lower then move the control box
inwards to release from mounting.
Inspect the motor drive assembly and control
unit for wear and damage, renew as necessary.
Refit
MOTOR DRIVE ASSEMBLY AND CONTROL UNIT
NOTE: The following servicing of the sunroof
assembly can be carried out without removing
the complete sunroof assembly.
12. Check timing of the control unit to sunroof. A
Remove
1. Fully close the sunroof then disconnect the
battery negative terminal.
2. Turn to release the two turnbuckles to access
the motor drive assembly and control unit,
located behind the switchplate.
3. Remove the switchplate and disconnect the
two multiplugs from the switch and courtesy
light.
8
CAUTION:The motor drive assembly gear will not
mesh correctly with the drive cables if the metal
insert is NOT refitted.
11. Refit the control unit.
Remove and refit
6
10. Refit the motor drive assembly ensuring the
metal insert is fitted.
V’shaped notch should be visible through the
slot in the control unit when the sunroof is in
the fully closed position.
13. Reverse the removal instructions 2 to 5.
14. Fully check the sunroof operates correctly.
Recode the radio.
ADDITION: SEPT. 90
.
: ‘.’ :.:.::
GLASS SUNROOF COMPLETE ASSEMBLY
RR2914M
Remove and refit
Remove
_.
1. Fully open the sunroof rearwards then
disconnect the battery negative terminal.
2. Remove the switchplate and disconnect the
two multiplugs from the switch and courtesy
light
3. Remove the headlining completely from the
vehicle
4. Remove the four clips and disconnect the
drain tubes
5. Disconnect the multiplug from the control unit
to the main harness.
6. With assistance remove the eight nuts and
washers and two bolts. Lower the complete
sunroof assembly to enable it to be removed
through the rear of the vehicle.
8. With assistance lift the complete sunroof
assembly to the roof panel.
9. Locate and fit loosely the eight retaining nuts
and washers and two bolts.
10. Ensure the closed sunroof now fits equally
positioned in the roof panel aperture. Tighten
the retaining nuts and bolts, recheck fit.
11. Reconnect the electrical multiplugs to the
main harness and sunroof switch.
12. Fully check the sunroof operates correctly and
leave in the open position.
13. Disconnect the sunroof switch
14. Fit and secure the drain tubes with retaining
clips.Water test to ensure a watertight seal.
15. Fit the headlining and sunroof trim.
16. Reconnect electrical multiplugs to sunroof
switch and interior light then fit switchplate.
17. Close glass sunroof and draw sunshade.
Recode the radio.
Refit
I
:I’-
7. Manually operate the sunroof to the fully
closed position.On completion of manual
operation t h e m o t o r s p i n d l e M U S T B E
TURNED BACK HALF A TURN TO ENSURE
ENGAGEMENT TO THE ELECTRICAL DRIVE
MOTOR.
,’
:.,
ADDITION: SEPT. SO
76
RANGE
lggl R O V E R
CHASSIS AND BODY
SLIDE AND GUIDE CHANNEL ASSEMBLIES OR
SUNSHADE PANEL.
RR2929M
‘.
\\
Remove and refit
NOTE: The following servicing of the sunroof
assembly can be carried out without removing
the complete sunroof assembly.
The sunshade panel is removed by releasing,
either the left or right slide and guide channel
assembly, instructions 1. to 12.
6. Move the tilt slide forwards until the location
cam has reached the position it would
normally locate into the locator block.
Manually adjust the cam outwards to allow the
tilt slide to pass and to attain the full tilt
position.
Remove
1. Remove glass panel assembly.
2. Remove sunroof wind deflector assembly.
3. Remove rear crossmember drainchannel.
4. Move the tilt slide rearwards until the location
cam is clear of the locator block.
5. Remove the locator. block.
RR2930M
7. The drive cable end is now accessible.
RR2929M
7
0
Disconnect drive cable from the slide
assembly.
8. Push the tilt slide rear-wards reversing
instruction 6.
9. Push complete slide assembly rearwards
approximately 2”.
10. Remove front end stop and the attaching
screw from centre of guide channel.
’ :I
“..
i
ADDITION: SEPT. SO
.,..:
;“d”g 1991
CHASSIS AND BODY
‘.
2. To check timing of the control unit when the
glass sunroof panel is removed. A V’shaped
notch should be visible through the slot in the
control unit when the sunroof tilt mechanism
is in the position shown.
11. Push guide channel assembly out sideways to
release guide channel from the roof panel.
12. Slide the sunshade panel forward and lift out
of runner to remove.
I
\.
Continue for removal of slide and guide
channel assembly.
13. With the aid of a flashlight directed between
the roof panel and sunroof assembly. Observe
for reassembly the guide channel rear spring
fixing point.
14. Pull the guide channel forward to release from
the rear spring fixing point. Remove the guide
channel asembly
Refit
15. Reverse the removal instructions
16. Fully check the sunroof operates correctly.
TIMING OF CONTROL UNIT TO SUNROOF
OPERATION.
:*
‘.
The timing of control unit to sunroof operation will
be disturbed:If the sunroof position is altered when the control
unit is removed.
Or the control unit is removed and the control unit
gear is moved manually.
1. To check timing of the control unit to sunroof.
A V’shaped notch should be visible through
the slot in the control unit when the sunroof
is in the fully closed position.
.6327hl
7
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