Land Rover Defender 90 110 Workshop 1984 Rover Manual
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CHASSIS AND BODY El .. . . .... r”,,.. ’: ., , . :I 4.:: : . ... .~. A FrontDatum B Chassis Datum C Front axle centre line D Rear axle centre line 1. 4148 - 4143 mm 2. 40093-4005 mm 3. 978,7-981,2 mm 4. 22-20” 5. 252-250 mm 6. 239-236,5 mm 7. 3023,3-3022,3 mm 8. 3030,7-3028,7 mm 9. 155- 153 mm 10. 871,2-869,2 mm 11. 2794 mm - Wheelbase 12. 488 - 433 mm 13. 488 - 433 mm 14. 82-79,5 mm 15. 750,9 mm 16. 750,9 mm 17. 4393 - 4363 mm 18. 4393 -4363 mm 19. 2993 - 2953 mm 20. 500-495 mm 21. 500 - 495 mm 22. 594,2-593,4 mm -- LAND ROVER 110 CHASSIS ALIGNMENT DIMENSIONS 23. 594,2 - 593,4 mm 24. 283 - 282,2 mm 25. 283 - 282,2 mm 26. 1970- 1968 mm 27. 642,9-639,5 mm 28. 590,5 mm 29. 295,25 mm 30. 136,5 mm 31. 103 - 100 mm 32. 1177,5- 1175,5 mm 33. 1692,5 - 1689,5 mm 34. 2610-2606 mm 35. 2040,5 -2037,5 mm 36. 1912,5 - 1909,5 mm 37. 1359- 1357 mm 38. 1573- 1571 mm 39. 270 - 268 mm 40. 665,5-633,5 mm 41, 440 - 438 mm I. . 5
176 I CHASSIS AND BODY REMOVING THE DOOR TRIM - Front and rear doors 1. Prise off the two finishers and remove the two screws securing the door pull. -. -- .___ - ...- . 1. 5. Lever off the window regulator center finisher and remove the retaining screw and withdraw the handle and bezel. 2. Remove the single Screw behind the remote control 6- Using a screwdriver, the trim away lever. from the door. 3. Prise off the remote control lever bezel. Fitting door trim 7. Remove any trim fasteners held in the door panel and insert them into the back of the trim or use new ones. 8. Ensure that the anti-vibration pads are in position and offer -up the trim to the door, lining-up the fasteners with the holes in the door and push the trim into position. 4. Prise off the door locking button bezci. , 8
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