Land Rover Defender 90 110 Workshop Book 4 Rover

							CHASSIS AND BODY 
. I. ,. 9. Fit the  bezels  to  the  locking  button and  remote 
10. Fit  the  single screw  behind  the  remote control 
11. Fit the door  pull and secure  with two screws  and 
12. Fit the  window  regulator  handle and retain  with the 
control 
lever. 
lever. 
finishers. 
single screw  and finisher. 
,  ~ .. I. I 
76 
REMOVING 
WINDOW REGULATORS - rear side 
door 
Fitting regulator 
channel. 
5. Insert  the lifting  arm button  into  the  lifting 
To remove 
1. Remove  the door trim. 
2. Remove the  protective weather sheet. 
3. Temporarily  fit the handle  and wind  the window  up 
position,  with a  length 
of timber,  to  prevent it 
falling when removing  the regulator. 
4. Remove the  four  screws retaining the regulator to 
the  mounting  panel and withdraw  the regulator 
whilst  sliding  the lifting arm  button  from the lifting 
channel. 
To assist  this operation,  remove the 
timber  and lower  the glass. 
. - to its  fullest  extent and support  the  glass  in this 
r-----.-----. - -1 
c-- --- -/-- ST1903M 
6. Position  the regulator so that  the fixing  holes 
line
-up  with  the holes in the  mounting  panel. 
7. Secure with the four  screws and  tighten  evenly. 
8. Temporarily  fit the  handle  and check  that glass can 
be  raised  and  lowered  smoothly without tight 
spots. 
9. Fit  the weather protection  sheet with adhesive. 
10. Fit the door trim,  regulator handle,  door pull, and 
bezels. 
9  
						

							76 
REMOVING EXTERIOR HANDLE - rear side door 
CHASSIS AND BODY 
To remove 
1. Remove the door  trim,  regulator handle, door pull 
and bezels. 
2. Peel  back  sufficient  of the  weather protection  sheet 
to  gain  access 
to the handle  mechanism. 
3. Disconnect  the  actuating  rod from  the handle 
operating  lever. 
4. Remove the  two  screws  and  withdraw the handle 
and  bezels. 
Fitting 
handle 
5. Fit the  handle  to the  door  ensuring  that  the two 
bezels  are 
in position - flat faces  towards  the door 
and  secure  with the two  screws. 
STi904M’ 
6. 
7. 
8. 
Connect  the actuating  rod to the  handle  operating 
lever  and secure  with spring  clip. 
Re-scal the weather  protection  sheet. 
Fit  the  door  trim, regulator  handle, door  pull and 
bezels. 
RENEWING  DOOR LOCKING  BUTTON - rear side 
door 
To remove 
1. Remove  the door  trim, regulator handle, door  pull 
and  bezels. 
2. Peel back  sufficient  of the weather  protection sheet 
to reveal the mechanism. 
3. Release  the  spring clip securing  the  button  to  the 
operating  rod and  withdraw 
the rod from the 
button. 
4. Remove  the two screws securing  the button  to the 
door  panel  and remove  the button. 
Fitting  locking  button 
5. Secure  the locking  button assembly  to the  door 
panel  with the two  screws. 
6. Fit the  operating  rod to the  button  assembly  and 
secure  with the spring  clip. 
7. Reseal  the weather  protection  sheet  and fit the 
door  trim,  door 
pull, regulator  handle and bezels. 
10  
						

							CHASSIS AND BODY 176 
RENEW REMOTE  CONTROL  LEVER - rear side 
door 
To remove 
1. Remove  the door  trim,  door pull, regulator  handle 
2. Peel-back sufficient  of the  weather protection  sheet 
3. Remove the spring clip and disconnect  the control 
and 
bezels. 
to  gain  access  to the  remote  lever. 
rod from  the locking  button. 
Fitting control  lever 
9. Fit the  plastic  retaining  clips to the  rod  assembly 
10. Connect  the control  rods to the latch  assembly and 
11. Fit the plastic  retaining  rod clips  to  the  mounting 
12. Connect  the  control  rod  to the  locking  button and 
13. Re-seal the  weather  protection sheet and fit the 
into 
position  and secure  with the two  screws. 
secure  with the clips. 
panel. 
secure  with the clip. 
trim  panel,  regulator  handle, door pull and bezels. 
REMOVE  DOOR LATCH  ASSEMBLY - rear side 
door 
To remove 
1. Remove  the  door pull, regulator  handle,  bezels 
2. Peel-back sufficient of the weather  protection sheet 
3. Release the remote  control lever rod from the latch 
4. Disconnect  the door  outer  handle  control  rod from 
and 
door  trim. 
to reveal  the latch. 
assembly. 
the  latch assembly. 
5. Disconnect  the door  locking  button remote  control 
6. Remove the  three  retaining screws and withdraw 
4. Release  the spring  clip  and disconnect  the  short 
locking  button  control  rod from  the latch 
mechanism. 
5. Disconnect  the long  remote  control  rod  from  the 
latch assembly. 
6. Remove  the two  screws  securing  the remote 
control lever  to the mounting panel. 
7. Release  the control  rods from  the  plastic  retaining 
clips  located  in the  mounting panel. 
8. Withdraw  the  remote  control  lever and rods  from 
the door.  rod 
from the  latch mechanism. 
the  latch assembly  from the door. 
continued 
SI ’ , 
11  
						

							76 
Fitting the latch 
7. Fit the  latch  assembly  to the  door  and secure  with 
the  three  screws, noting that  the uppermost  screw 
is longer. 
8. Connect the remote  control  levers to  the  latch 
mechanism  reversing instructions 
3,4 and 5. 
9. Re-seal the weather  protection  sheet  and fit the 
regulator handle,  door pull, door  trim and bezels. 
CHASSIS AND BODY 
REMOVING DOOR GLASS - rear  side door 
To remove 
1. Disconnect  the door  check  rod from  the door  post. 
2. Remove  the regulator  handle,  door  pull, bezels 
3. Remove  the weather protection sheet. 
5. Disconnect  and remove  the door  locking  button. 
6. Disconnect  the  control  rods from the latch  and 
and door 
trim. 
. 4. Remove the window  regulator  assembly. 
door outer  handle mechanism.  Remove 
the four  screws  retaining  the mounting 
e 
panel to the door  and remove  the  panel  complete 
with  rods  and control  lever. 
ST191OM // 
8. Remove the  single self tapping  screw to remove the 
water channel. 
9. Remove the  door check torsion  bar. 
10. Remove  the door check  rod by bending  back the 
end stop to enable the rod to be withdrawn. 
12  
						

							CHASSIS AND BODY (761 
.: 
. . :.... .Y. ..L.-? 
11. Remove the four  self-tapping  screws - two each 
12. Remove  the inner  and outer  weather  strips from 
.*.
						

							1761 CHASSIS AND BODY 
REMOVING MOUNTING  PANEL - front doors 
To remove 
1. Remove  the  door  trim, window regulator,  door 
pull,  bezels  and weather  protection  sheet. 
2. Remove the four  screws  securing  the window 
regulator  to the  mounting  panel. 
3. Remove the five screws securing  the mounting 
panel  to the  door frame. 
4. Release  the remote  control  lever rod from the  latch 
mechanism  and from  the plastic  clip 
in the 
mounting panel. 
5. Slide the  window regulator  arm from  the mounting 
panel  channel  and  remove  the panel with the 
remote  control lever  and rod. 
Fitting mounting  panel 
6. Engage the  window regulator arm  in the  mounting 
panel  channel. 
7. Connect  the remote  control  rod  to the  latch 
mechanism  and secure with the clip. 
8. Fit  the  mounting  panel and retain  with the five 
screws. 
9. Secure the  window regulator  to the  mounting  panel 
with  the four  screws. 
10. Raise and  lower  the window  to check  for free 
movement. 
11. Fit  the  weather  protection  sheet,  door trim, 
window  regulator  handle, door pull and bezels. 
REMOVING  DOOR LOCKING  BUTTON - front 
doors 
To remove 
1. Remove  the  door trim regulator  handle,  door pull 
2. Peel back  sufficient of the weather  protection  sheet 
3. Release  the  spring  clip and disconnect  the 
4. Remove the  two  screws and withdraw  the locking 
and 
bezels. 
to  expose  the mechanism. 
operating  rod from  the latch mechanism. 
button  assembly. 
continued 
14  
						

							CHASSIS AND BODY El 
i.2: I -.. ‘I .. ” Fitting locking  button 
Fitting regulator 
5. Secure  the  locking button assembly to the door 
with  the two  screws. 
6. Connect  the operating rod  to the  latch  mechanism 
and  secure  with the spring  clip. 
7. Reseal  the weather  protection  sheet and fit the 
door 
tnm, door  pull, regulator  handle, and  bezels. 
.. . 
REMOVING WINDOW REGULATOR - front doors 
To remove 
6. Insert the regulator  operating  arms  into  the 
channels. 
7. Fit  and  tighten  the mounting  panel lower screws 
and  tighten  the upper  screws. 
8. Position  the holes  in  the regulator  to line-up  with 
the  holes  in the mounting panel and secure  with the 
four  screws. 
9. Temporally  €it the  regulator  handle  and check  that 
the  glass  can  be  raised  and lowered  without  tight 
spots. 
10. Secure the  weather protection  sheet with adhesive. 
11. Fit the  door trim,  regulator  handle,  door  pull and 
bezels. 
1. Remove  the door  trim. 
2. Remove the weather  protection  sheet. 
3. Temporarily  fit the  handle and  position the window 
half  open  and support  with a length 
of timber. 
4. Remove the  two  lower screws  securing  the T doors  ~ mounting  panel 
to the  door  and  slacken  the  three 
upper  screws. 
5. Remove  the four  screws  retaining  the window 
regulator  to the  mounting  panel and slide  the 
1. Remove  the  door pull,  regulator  handle,  bezels 
operating  arms from  the channels  attached to the 
glass  and mounting  panel  and remove  the 
2. Peel back sufficient of the weather  protection sheet 
regulator. 
3. Release  the spring  clip and  disconnect  the control 
4. Release  the control  rod from the  plastic clip in the 
REMOVE  REMOTE CONTROL  LEVER - front 
To remove 
and door  trim. 
to  gain access  to the  remote  lever. 
rod from the  latch mechanism. 
4 mounting panel. 
continued  15  
						

							76’ 
5. Remove the  two  screws  securing  the remote 3. Disconnect  the operating  rod  from  the  handle 
control  lever to the  mounting  panel  and withdraw 
the lever  and control rod.  mechanism. 
4. Disconnect 
the rod from  the locking barrel  lever. 
CHASSIS AND BODY 
Fitting remote  control  lever 
6. Feed  the  control  rod  into position  and loosely 
secure  the lever 
to the  mounting panel  with the two 
screws. 
7. Connect  the  control  rod  to  the latch  mechanism 
and  secure  with the spring  clip. 
8. Tighten the control lever retaining  screws. 
9. Secure the  control  rod  to the  plastic  clip in the 
10. Secure the weather  protection  sheet with adhesive. 
11. Fit the  door trim,  regulator handle,  door pull and 
mounting panel. 
bezels. 
REMOVING  EXTERIOR  DOOR HANDLE - front 
doors 
To  remove 
1. Remove  the regulator  handle, door pull,  bezels 
and  door  trim. 
2. To gain access  to the  handle  mechanism,  remove 
the  mounting  panel  and  support 
the glass  with 
timber. 
sTi 982~ 
5. Remove the  two screws  and withdraw  the handle 
assembly 
. 
Fitting  the handle 
6. Fit  the  handle  to the  door  ensuring that the two 
bezels  are in position 
- flat  faces  ’towards  the 
door,  and secure  with the two  screws. 
7. Connect the rod  to the handle  operating lever and 
secure  with the spring clip. 
8. Connect  the rod  to the  locking  barrel lever and 
retain  with the spring  clip. 
8. Carry-out the instructions  for  fitting the  mounting 
panel and  door trim and fittings. 
16  
						

							CHASSIS AND BODY 
REMOVE THE DOOR LATCH ASSEMBLY - front 
doors 
76 
To remove 
1. Carry  out the  instructions tc remove  the mounting 
2. Disconnect  the  control  rod from  the handle 
3. Disconnect  the control  rod  from the locking  lever 
4. Disconnect  the locking  button control rod  from the 
panel 
and support  the glass with  timber. 
operating  lever. 
on  the  handle. 
latch  mechanism. 
ST1983M 
5. Remove  the  two  screws  and  remove  the  handle 
assembly from  the door. See exterior door handle. 
6. Remove  the  two  self-tapping screws retaining  the 
lower  end 
of the window  glass runner. 
ST 1 977 M 
7. Remove  the  three screws  securing  the latch 
assembly to  the door. 
8. Whilst  taking  care not to damage the runner,  ease 
it  away  from the latch  and  manoeuvre  the  latch 
assembly  from the door: 
Fitting latch assembly 
9. Carefully  ease the window  runner away, 
sufficiently  to  enable the latch  to be  located  into 
position. 
10. Secure the  latch to the door with the three  screws. 
11. Secure  the window  runner with the  two  screws 
ensuring  that the packing  strip is in  position  and 
that  the screw  heads  are below  the  bottom  of the 
runner  to prevent  damage  to 
the glass. 
12. Fit the  handle  with the  two  screws, ensuring  that 
the  bezels  are in position. 
13. Connect  the control  rod to the  handle  operating 
lever  and secure  with the spring  clip. 
14. Connect  the control  rod  to the  locking  lever and 
retain  with the spring  clip. 
15. Connect the  locking button control  rod to the latch 
lever and  secure with the spring clip. 
16. Carry-out  the  instructions  to fit the mounting 
panel. 
17. Fit  the door trim,  regulator handle,  door pull, and 
bezels. 
17  
						

							76 
REMOVING GLASS - front doors 
CHASSIS AND BODY 
To remove 
1. Carry-out the instructions  to remove  the 
2. Remove  the window  regulator. 
3. Push the glass  up to the  top of its travel  and support 
with a  suitable length 
of timber. 
4. Remove  the two self tapping  screws securing  the 
window  glass runner  on  the latch side 
of the door 
and  the single  screw  from the hinge  side. 
mounting 
panel. 
I 1 
ST1976M 
5. Taking care not to damage  the paint  work,  prise 
6. Remove  the timber  support  and lower  the glass  to 
the 
exterior  waist weatherstrip  from the door. 
the  bottom 
of the door. 
7. Ease  the runner  from the glass  at the  hinge  side of 
the door,  lift the  glass  over the bottom  edge of the 
door  and withdraw. 
I 
ST1968M 
Fitting glass 
8. Insert  the glass  into  the  runners at an  angle  as 
illustrated. 
9. Whilst  lifting the glass,  position it squarely in the 
runners  and  raise 
it to the  top of its  travel  and 
insert  the timber  support. 
10. Secure the  hinge side runner  with the single  screw 
ensuring  that the packing  strip is in position. 
continued 
18