RN Defender Restoration Guide 02 2013 PDF
RN Defender Restoration Guide 02 2013 PDF
RN Defender Restoration Guide 02 2013 PDF
Haynes
Restoration
Manual
DEFENDER 90 NAS Owner’s Manual DEFENDER
As equipped in 1994, 95, 1997 Defender 90. BOOK57
Reproduced from factory original. $ 34.60
1994, 95 Defender 90 NAS Owner’s Manual........RNS571 $ 129.50
1997 Defender 90 NAS Owner’s Manual..............RNS572 $ 129.50
For owners who intend to keep their Land Rover forever, we are excited to
offer you our new selection of original manufactured galvanized chassis.
The foundation of any great Land Rover. No component better exemplifies
Land Rover strength, no component more effects its value. So we have started with the best.
Our entire range of Defender chassis are assembled on factory jigs to ensure exacting dimensional accuracy. Bare
units are then enhanced with features unique to NAS Defender. This allows us to offer you a direct replacement for early
NAS vehicles with all the improvements found on latest Puma models. Then each chassis is hot dipped galvanized to en-
sure a lifetime of corrosion resistance.
Experience has taught us that one chassis does not fit all. Some owners want to restore their Land Rover to original
factory condition and some building their ultimate Land Rover, want to fit other engines or bodies offered by Land Rover.
So we have taken our most requested chassis models to create this selection for you.
In addition to our NAS chassis selection we also offer original manufactured replacement bulkheads for NAS 90s and
galvanized replacement foot well panels for both NAS 90 and 110 to help solve your corrosion issues. North America’s number one choice for
Please feel free to contact us with questions and for product advice. The entire range of Land Rover Genuine Parts is chassis selection at Rovers North.
available through Rovers North. We have lots of knowledge and experience to share and look forward to helping you with
your next project.
Defender 90 NAS
Galvanized Chassis
Shown RNC878
Updated
Reinforced
bulkhead
outriggers
Defender 110 V8
Galvanized Chassis
shown RNH710
A
B
Puma rear crossmember features
A. Adjustable body mounting bracket. C
B. Integral fixing nuts for tow plate - for easy mounting.
C. Recessed mounting for towing plug - for better protection.
D. Bottom mounting blocks for rear NAS step.
*Updated Genuine plastic fuel tank kit (Includes; fuel tank, pump,
sender unit, mounting bracket, rear sway bar and harness link).......RNK4297 $ 951.39
Defender 90 with Rovers North Galvanized Chassis custom built by Congleton Racing and Restoration.
A
9 A Bulkhead Assembly, LHD Defender V8 NAS 90
Made from the latest Land Rover Galvaneal metal and electrostatic primed for superior
corrosion resistance. This is an exact replacement for NAS 90 models. Requires upgrading
11 to the latest wiper wheel boxes offering improved wiper arm performance. Supplied ready
for paint. For upgraded wiper wheel boxes use RNS555. Assembled in the USA.
1. 1995 NAS 90 (will easily adapt to 1994), includes #7...........................RNB1995 $ 2599.00
5 1997 NAS 90, includes #7 ...........................................................................RNB1997 $ 2785.00
10 Updated Wiper Wheel Boxes Kit.............................................................RNK1995 $ 159.95
8 2. Plug.................................................................................................................RNN681 $ 7.61
7 3. Bonnet Buffer, Genuine .............................................................................RNB821 $ 16.95
6
Bonnet Buffer, ProLine ...............................................................................PLB821 $ 2.95
4. Plug.................................................................................................................RNN686 $ 2.98
4 5. Drain Channel Seal ....................................................................................RNN687 $ 46.11
6. Wiper Spindle Blanking Plug to #1A622423........................................RNN688 $ 3.22
Blanking Plug 12x18mm from #2A622424...............................................RNN689 $ 0.98
1 Dash Vents
7. Dash Vent Lid Assembly RH.....................................................................RNN703 $ 79.95
Dash Vent Lid Assembly LH.......................................................................RNN704 $ 79.95
Pin....................................................................................................................RNB846 $ 5.95
8. Rubber Seal, Genuine ................................................................................RNE365 $ 23.50
Rubber Seal, ProLine ..................................................................................PLE365 $ 20.95
9. Flyscreen.......................................................................................................RNI049 $ 119.95
14 Pop Rivet........................................................................................................RNN705 $ 0.65
10. Vent Control Lever up to 1A622423 .........................................................RNI037 $ 67.95
Vent Control Lever from 2A622424, RH ..................................................RNI669 $ 169.95
Vent Control Lever from 2A622424, LH...................................................RNI670 $ 169.95
11. Air Vent Knob from 2A622424...................................................................RNI673 $ 5.66
12. Replacement Door Post, LH.....................................................................CHAS17 $ 119.95
Replacement Door Post, RH......................................................................CHAS18 $ 119.95
3 13. Bulkhead to Chassis Hardware Kit (2 bolts, 2 nuts and washers) RNK4261 $ 44.40
14. Spire Nut - Wing / Bulkhead.....................................................................RNC815 $ 1.65
2 Bolt for Spire Nut.........................................................................................RNC844 $ 1.96
13 12
1
Rear Chassis Cross-Member
Replacement parts
PLH619G $ 389.00
RNF0014 Defender 90 NAS Galvanized
Rear Cross Member
2 LHF Inner 3
*All parts are galvanized except RNF0020 which is painted. Defender 110
Replacement
PLH619110 $ 399.00
Cross Member with 18” Extensions
B Defender NAS 90, 110 Replacement Floor Footwell Panels
Reproductions of exact factory units, these hand crafted 18 gauge steel units are galva-
nized* and ready to fit into your Defender for a proper restoration.
1. Floor Panel, LHF Outer, 90/110 NAS, galvanized..................................RNF0012 $ 69.95
Floor Panel, LHF Inner, 90/110 NAS, galvanized ...................................RNF0014 $ 45.95
Floor Panel, LHF Upper 90/110 NAS, galvanized ..................................RNF0018 $ 89.95
Floor Panel, RHF Inner 90/110 NAS, galvanized ...................................RNF0015 $ 45.95
Defender 90
Floor Panel, RHF Outer 90/110 NAS, galvanized...................................RNF0013 $ 69.95 PLH61990 $ 398.00
Floor Panel, RHF Upper 90/110 NAS, galvanized..................................RNF0019 $ 79.95 Replacement
2. Kick Panel, LHF Outer 90/110 NAS, galvanized ...................................RNF0016 $ 49.95 Cross Member with 18” Extensions
Kick Panel, RHF Outer 90/110 NAS, galvanized....................................RNF0017 $ 49.95
3. Kick Panel, LHF Inner 90/110 NAS, painted steel.................................RNF0020 $ 119.95
Kick Panel, RHF Inner 90/110 NAS, galvanized.....................................RNF0021 $ 69.95
PLI243
C
1 2 Replacement chassis parts
Welding is required to install these parts and should be
C Defender Chassis Parts
referred to a professional. For the do-it-yourself Land
1. Crossmember Assembly NAS V-8 Galvanized, ProLine....................PLI243 $ 259.95
Rover owner the job requires a cut off wheel and/or
Crossmember Assembly from Tdi, Td5...................................................RNI329 $ 159.92
torch, 4” grinder and a 60 amp welder. Try 3/32” 6011
2. Bulkhead Outrigger RH, Genuine ...........................................................RNI545 $ 226.45
rods at 60 amps (45 amps DC) for best results.
Bulkhead Outrigger RH, ProLine ..............................................................PLI545 $ 89.95
Bulkhead Outrigger LH, Genuine .............................................................RNI546 $ 221.34
Bulkhead Outrigger LH, ProLine...............................................................PLI546 $ 89.96
A Defender Seatbase A
1. Front Main Floor Panel, RH LT 85 V8 Petrol .........................................RNS299 $ 163.43
Front Main Floor Panel, RH LT 77 2.5L 4CYL, 5CYL TDI........................RNS300 $ POA
2. Front Main Floor Panel, LH LT 85 V8 Petrol............................................RNS301 $ 222.66
Front Main Floor Panel, LH LT 77 2.5L 4CYL, 5CYL TDI.........................RNS302 $ 163.43
Front Main Floor Panel, LH 4CYL Petrol, 2.5L NA Diesel.....................RNS303 $ 23.26
Floor Screw Kit, Defender 90, V8 ............................................................RNK890 $ 169.95
Floor Screw Kit, Defender 110, V8 ...........................................................RNK8110 $ 139.95
3. Self Tapping Screw up to #3A654045.....................................................RNH042 $ 1.95
Self Tapping Screw from #3A654046.......................................................RNS304 $ 2.64
6
4. Plain Washer 6M ........................................................................................RNN986 $ 0.85
5. Lokut Nut .......................................................................................................RNC946 $ 1.49
7 10
6. Screw M6x20MM .......................................................................................RNH483 $ 0.49 8
7. Washer M6 ...................................................................................................RNF420 $ 1.49
8. Sprung Washer M6 ....................................................................................RNF428 $ 2.34 9 1 11
9. Hex Nut M6...................................................................................................RNF731 $ 0.95 13
10. Bolt up to #3A654045...................................................................................RNB701 $ 1.59 12
Bolt from #3A654046....................................................................................RNS304 $ 2.64
11. Washer M6 ...................................................................................................RNF420 $ 1.49
12. Spiralok Nut 110..........................................................................................RNS305 $ 2.14
Spire Nut 90...................................................................................................RNB681 $ 1.59
13. Seal - Cut to Length.....................................................................................RNN985 $ 12.06
Defender Tunnel Panel
14. Diaphragm Assembly Panel 2.3, 2.5L, 200 Tdi (shown) .....................RNN983 $ POA
Diaphragm Assembly Panel 3.5, 3.9 V8, 300 Tdi, Td5...........................RNN984 $ 119.95
13 27
15. Seal.................................................................................................................RNN985 $ 12.06
16. Self Tapping Screw....................................................................................RNH042 $ 1.95
17. Plain Washer 6M ........................................................................................RNN986 $ 0.85
18. Tunnel Assembly.........................................................................................RNN987 $ 312.27
19. Self Adhesive Packing Strip - Cut to Length.......................................RNN988 $ 28.64
20. Loknut Nut.....................................................................................................RNC946 $ 1.49
16 26
21. Transfer Case Cover, V8 (part of seatbox on R380).............................RNN989 $ POA
22. Flanged Head Screw M8x20MM............................................................RND942 $ 1.59
23. Washer...........................................................................................................RNX034 $ 1.39
28
24. Sprung Washer M8 ....................................................................................RNF428 $ 2.34
17
19
25. Hex Nut M8...................................................................................................RNE157 $ 0.95 20
26. Gear Lever Assembly Gaiter - less EFI..................................................RNH417 $ 49.95
Gear Lever Assembly Gaiter - with EFI...................................................RNN990 $ 76.17
19
27. Cable Tie........................................................................................................RNN991 $ 14.52
28. Insulation Pad 4 Cylinder ..........................................................................RNN992 $ 60.74
Insulation Pad V8 .........................................................................................RNN993 $ 66.91
Defender Seatbase Assembly 18
29. Center Seatbase Lid Assembly w/o tunnel Consol up to 2007 ........RNS315 $ 71.63 15
Center Seatbase Lid Assembly w/tunnel Consol up to 2007 ............RNS316 $ 63.87
Center Seatbase Lid Assembly From 2007 on.......................................RNS317 $ 53.99
30. Battery Compartment Lid..........................................................................RNS318 $ 47.36 19
31. Locker Lid for Vehicles for Vehicles w/Additional Fuel Tanks
from #HA455946 TO #LA932671.................................................................RNS319 $ 58.86
Locker Lid for Vehicles w/Additional Fuel Tanks from #LA932672 ...RNS320 $ 244.30 16
20 17
Locker Lid for Vehicles w/o Additional Fuel Tanks up to #WA159806.RNS321 $ 204.67
14
Locker Lid Assembly from #XA159807 ....................................................RNS322 $ 58.86
32. Self Taping Screw......................................................................................RNC795 $ 0.64
33. Washer M6 ...................................................................................................RNF420 $ 1.49
34. Spirallok Nut ................................................................................................RNS323 $ 0.85 42. Screw M6......................................................................................................RND909 $ 1.00
35. Rear Seat Stop to #HA455945...................................................................RNS324 $ 55.81 43. Plain Washer ...............................................................................................RNI804 $ 0.90
Rear Seat Stop from #HA455946 ..............................................................RNS325 $ 12.02 44. Spring Washer M6......................................................................................RNF428 $ 2.34
36. Overcenter Catch........................................................................................RNS326 $ 14.31 45. Hex Nut M6 up to 2007...............................................................................RNF731 $ 0.95
37. Pop Rivet .......................................................................................................RNS327 $ 1.56 Flange Nut from 2007 on............................................................................RNS331 $ 1.93
38. Blanking Plug 13MM.................................................................................RNB875 $ 0.48 46. Blanking Plug from 2002 on .....................................................................RNN785 $ 4.61
Blanking Plug 50MM...................................................................................RNB883 $ 1.79 47. Hex Nut 5M 1996 - 2006..............................................................................RNI217 $ 0.75
Blanking Plug 14MM...................................................................................RNB876 $ 0.75 Flange Nut from 2007 on.............................................................................RNS332 $ 1.56
Blanking Plug 30MM...................................................................................RNN686 $ 2.98 48. Gasket 1996 - 2006.......................................................................................RNS333 $ 7.93
Blanking Plug 25.5MM................................................................................RNB880 $ 1.59 49. Stud 1996 - 2006............................................................................................RNS334 $ 11.89
39. Plate - Right Hand Drive V-8 .....................................................................RNS328 $ 111.37 50. Flange Nut M6 1996 - 2006 ........................................................................RND756 $ 1.59
40. Pop Rivet .......................................................................................................RNC690 $ 0.95 51. Immobiliser Housing Box 1996 - 2006 ...................................................RNS335 $ 37.85
41. Extension Panel RH up to #HA455945....................................................RNS329 $ POA 52. Immobiliser Box Lid 1996 - 2006................................................................RNS336 $ 41.94
Extension Panel LH up to #HA455945......................................................RNS330 $ POA 53. Monobolt.......................................................................................................RNS337 $ 4.09
67 31 32
66
33
34 29
64
30
41
37
35
36
41 61
59 60
58
21
57
56
40 55
39
38 65 54
46
63
25
42
36
24
23 43 53
22 37
16
52
13
44 62
20 17
48
3 45 47
51
4 2
50
5 49
13
54. Screw M6x20MM ......................................................................................RND909 $ 1.00 65. Seatbase Assembly with Left Hand Battery Box for vehicles with side fuel tank
Screw M6x25MM........................................................................................RND758 $ 1.95 4 Cylinder models up to 1999 ...........................................................................RNS344 $ 2899.00
55. Plain Washer ...............................................................................................RNF434 $ 0.44 V8............................................................................................................................RNS346 $ 3016.71
56. Washer - Spring M6....................................................................................RNF428 $ 2.34 Seatbase Assembly with Left Hand Battery Box and Right Hand Tool Box
57. Lokut Nut .......................................................................................................RNS338 $ 2.14 for vehicles with rear fuel tank
58. Screw M6x20MM ......................................................................................RND909 $ 1.00 V8, Tdi....................................................................................................................RNS349 $ 436.89
59. Washer...........................................................................................................RNI804 $ 0.90 Td5..........................................................................................................................RNS348 $ 3167.39
60. Spring Washer M6......................................................................................RNF428 $ 2.34 Puma......................................................................................................................RNS349 $ 436.89
61. Hex Nut M6...................................................................................................RNF731 $ 0.95 66. Harness Grommet.......................................................................................RNS352 $ 20.44
62. Pop Rivet .......................................................................................................RNC690 $ 0.95 67. Tool Box Assembly 90 4.0L V8 .................................................................RNS353 $ 164.78
63. Battery Tray up to #WA159806 .................................................................RNS339 $ 967.08 Tool Box Assembly from #XA159807 .......................................................RNS354 $ 33.73
Battery Tray from #XA159807....................................................................RNS340 $ 95.55
64. Seal.................................................................................................................RNN985 $ 12.06
A
1
3
4 20
2
1
21 Superior Performance
5 18 19
Variable Rate Springs
17
PLS023G 7 6
Land Rover Genuine Coil Spring Kits
Defender 90, Coil Spring Set of Four, HD w/winch, Genuine ..............RNK5111 $ 325.44
8 16 Defender 90, Coil Spring Set of Four, Heavy Duty, Genuine.................RNK5101 $ 285.00
10 Defender 110, Coil Spring Set of Four, HD, Genuine .............................RNK5102 $ 278.19
9 14 15
22
11
13 B
4 2
12 10
6 3
11
5
15
10
A Front Suspension, LHD
7
1. Shock Tower, Defender, Genuine...........................................................RNS023 $ 84.95
9
Shock Tower, Defender, Galvanized, ProLine ......................................PLS023G $ 49.50
2. Securing Ring for Shock Tower, Genuine, each..................................RNS039 $ 25.95
Securing Ring for Shock Tower, HD, Terrafirma, pair incl. nuts .......TF502 $ 36.00 11
3. Nut (4 per ring required), Genuine...........................................................RNS034 $ 1.59 9
1
4. Locker for nut (4 per ring required), Genuine .......................................RNS037 $ 0.59 8
Front Coil Springs, Drivers Side
5. Defender 90 Standard, Genuine ..............................................................RNE444 $ 69.95 12
Defender 90 Heavy Duty, Genuine...........................................................RNS046 $ 69.95 14 13
Defender 110 Standard, Genuine.............................................................RNS050 $ 69.95
Defender 110 Standard, Proline ...............................................................PLS050 $ 49.95 B Land Rover Genuine Front Suspension - Anti-Roll Bar
Defender 110 Heavy Duty, Genuine.........................................................RNS046 $ 69.95 1. Anti-roll bar ..................................................................................................RNS481 $ 199.95
Front Coil Springs, Passenger Side 2. Bushing..........................................................................................................RNI868 $ 14.91
Defender 90 Standard, Genuine...............................................................RNE445 $ 69.95 3. Sway Bar Mounting Bracket ..................................................................RNS119 $ 10.95
Defender 90 Heavy Duty, Genuine...........................................................RNS047 $ 69.95 4. Nyloc Nut M10.............................................................................................RNE470 $ 1.79
Defender 110 Standard, Genuine.............................................................RNS051 $ 69.95 5. Bolt M10 x 35mm .........................................................................................RNS482 $ 4.56
Defender 110 Standard, Proline ...............................................................PLS051 $ 51.45 6. Plain Washer 10mm I.D.............................................................................RNF416 $ 0.95
Defender 110 Heavy Duty, Genuine.........................................................RNS047 $ 69.95 7. Ball Joint.......................................................................................................RNS124 $ 74.95
6. Spring Seat, Defender, Road Spring Seat, Genuine ...........................RNH058 $ 19.95 8. Lock Nut M16 ...............................................................................................RNH045 $ 1.19
Road Spring Seat, Proline..........................................................................PLH058 $ 10.80 9. Shock Bushing ............................................................................................RNS115 $ 3.08
7. Bolt M10 x 25mm (2 required per road spring seat), Genuine..........RNH059 $ 0.98 10. Plain Washer ...............................................................................................RNH041 $ 1.75
8. Lock Washer, Genuine ..............................................................................RNH011 $ 1.49 11. Pin ...................................................................................................................RNH050 $ 23.72
9. Bushing for Panhard Rod, Defender, Genuine.....................................RNS049 $ 13.95 12. Plain Washer M12 x 28mm OD................................................................RNH055 $ 0.50
10. Lock Nut - Defender, Genuine..................................................................RNS058 $ 3.28 13. Castle Nut 12mm .........................................................................................RNH037 $ 3.95
11. Bolt for Panhard Rod to axle bracket, Genuine ...................................RNS052 $ 7.95 14. Split Pin .........................................................................................................RNS483 $ 0.85
12. Panhard Rod Assembly with Bushings, Defender, Genuine............RNS024 $ 229.95 15. Complete Anti-Roll Bar Kit.......................................................................RNK4235 $ 272.81
13. Bolt, Radius Arm to Axle, Defender, Genuine.......................................RNC911 $ 5.95
14. Lock Nut for Radius Arm Bolt, Genuine.................................................RNS031 $ 2.95
Bushing for Radius Arm C Land Rover Genuine
15. Defender up to ‘94, Genuine .....................................................................RNE467 $ 26.95 Rear Suspension, LHD
Defender ‘94 on, Genuine ..........................................................................RNS060 $ 17.95 1. Rear Springs, Drivers Side
Front Radius Arm Assembly w/ Front Axle Bushings Defender 90 Standard.................................................................................RNS046 $ 69.95
16. Defender up to ‘94, Genuine .....................................................................RNE456 $ 499.95 Defender 90 Heavy Duty ............................................................................RNE526 $ 97.95
Defender ‘94 on, Genuine ..........................................................................RNH056 $ 389.95 Defender 110 Standard...............................................................................RNE431 $ 79.95
17. Dished Washer, Genuine..........................................................................RNS029 $ 4.65 Defender 110 Heavy Duty ..........................................................................RNE432 $ 69.95
18. Bushing Set, Front Radius Arm to Chassis, Genuine..........................RNS028 $ 5.95 Rear Springs, Passenger Side
19. Flat Washer, Genuine.................................................................................RNS027 $ 9.80 Defender 90 Standard.................................................................................RNS047 $ 69.95
20. Lock Nut, Genuine.......................................................................................RNS026 $ 9.95 Defender 90 Heavy Duty ............................................................................RNE527 $ 97.95
21. Front Shock Absorber w/bushings, Defender 90, Genuine ..............RNF336 $ 119.25 Defender 110 Standard...............................................................................RNE438 $ 119.95
Front Shock Absorber w/bushings, Defender 110, Genuine .............RNF338 $ 99.95 Defender 110 Heavy Duty ..........................................................................RNE436 $ 69.95
22. Front Axle Stops, Defender, Genuine.....................................................RNC879 $ 28.50 2. Spring Retainer, Defender 90...................................................................RNH061 $ 5.95
Front Axle Stops, Defender, ProLine .......................................................PLC879 $ 9.95 Spring Retainer, Defender 110..................................................................RNI518 $ 5.95
Terrafirma Pro
Sport +2 inch
Heavy Duty
Suspension Kits
Include; 4 Terrafirma +2
inch Pro Sport shocks and
4 +2 inch springs. Great off-
road, excellent on-road.
Defender 90, 1984-’02, Terrafirma Pro Sport HD Suspension Kit .......RNK725 $ 599.00
Defender 110, 1983-’02, Terrafirma Pro Sport HD Suspension Kit .....RNK727 $ 629.00
A B
RH Front 6
18
8 10 7 RH Rear
5
15 4 7
12 8 9
13 11 15 2
14
18
5
2
6
1
1 3
7
16 4
13 10
16 12
17 3 17
9 14 11
LH Front LH Rear
Defender
SBL2003E