Land Rover Defender 90 110 Workshop 1984 Rover Manual

							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  
						

							CHASSIS AND BODY 
I e 0 
76 
ST1967M 
11. Locate the packing  strip and  secure  the opposite 
runner  with the  two  screws. Ensure that all three 
screw  heads  are well  below  the bottom 
of the 
runners  to prevent  damage 
to the glass. 
12. Locate the  regulator in the  window lift  channels. 
13. Carry-out  the instructions  to fit  the  mounting 
14. Fit the  door trim,  window  regulator,  door pull and 
panel. 
bezels. 
REMOVING LOCKING BARREL -front doors 
  To remove 
ST1981M 
6. Withdraw  the lock  barrel  from the  exterior  door 
handle  complete  with the locking  sleeve. 
ST1980M 
1. Remove  the  regulator  handle,  door pull, bezels, 
2. Carry-out  the instructions  to remove  the mounting 
3. Raise  and support  the  glass to gain  access  to the 
4. Release  the spring clip  and disconnect  the rod from 
5. Remove  the single  screw  and withdraw  the lock 
door 
trim and weather  protection sheet. 
panel. 
latch  mechanism. 
the 
lock operating  lever. 
7. To remove the bane1 from  the  plastic retaining 
sleeve,  depress  the spring  loaded  button  and 
withdraw  the sleeve. 
lever  assembly. 
7 
ST1979M 
continued 
19  
						

							1761 CHASSIS AND BODY 
Refit the lock  barrel 
Note: 
If a new  barrel is being  fitted,  check  that  the 
number on  the  barrel coincides with the number 
on the 
accompaaing key. 
8. Push  the  plastic retaining  sleeve over the barrel 
until  the spring  loaded peg  locks it into position. 
9. Fit the  barrel  and plastic  sleeve  assembly  to  the 
locking  sleeve  and insert  into the exterior  handle 
reversing  instruction 
6. 
10. Assemble  the lock  lever components as  illustrated 
and 
from the  inside of the door  panel, fit them  to 
the  barrel  assembly with  the single  screw. 
ST1978M 
11. Connect  the  operating  rod  to the lock lever  and 
secure  with the spring  clip, reversing  instruction 
4. 
12. 
Fit  the  mounting  panel  and weather  protection 
sheet. 
Fit the  door  trim, regulator  handle, door 
pull  and bezels. 
20  
						

							Section 
Number 
rF* i=. ? - 
CONTENTS 
80 HEATER 
82 
-Remove and refit 
- Drive  belt adjustment 
AIR 
CONDITIONING  MAINTENANCE 
17 10 
. 
82 COMPRESSOR 
-Fan motors  remove  and refit 
-Condenser  rcmove and refit 
-Receiver drier  remove  and refit 
82 
18 
19 1 O 
CONDENSER 
82 
-Remove  and refit - L.H. Steering 
- Resistor  block - remove and refit 
-Blower  motor - R.H. Steering,  remove and refit 
EVAPORATOR 
20 
23 
24  
						

							Section 
Number 
86 
CONTENTS 
ELECTRICAL EQUIPMENT 
Page 
186 I ELECTRICAL PRECAUTIONS e 
-Polarity 
-High voltage  circuits 
- Connectors  and harncss 
-Battery disconnections 
-Battery  charging 
-General  precautions 
-Test equipment 
-Overhaul  V8 engine  distributor 
- Overhaul  four cylinder  engine distributor - Ducellier 
- Overhaul  four cylinder  cngine distributor - Lucas 
-Electronic  ignition distributor  type 35DMS - V8 engine 
-Electronic  ignition distributor  type 35DLM8 - V8 cngine 
-Overhaul  alternator - all models - Lucas Al 15-34 and  Al 15-45 
-Overhaul  alternator - all models - Lucas A127/65 
- Alternator  functional check 
-Diode fault symptoms 
-Alternator  fault and diagnosis  chart 
-Overhaul diesel engine  starter motor 
-Overhaul V8 engine  starter motor 
-Overhaul  four cylinder  petrol engine  starter  motor 
-Overhaul - Paris-Rhone 4 cylinder  Diesel engine  starter motor 
- Rcmovc  and refit  2.5 Turbo chargcd Diesel  engine  starter motor 
- Overhaul  Lucas M78R starter motor 
- Lamps 
- Overhaul  wiper motor  2 
4 
5 
7 
13 
pL 
20 k.;: 
24 
28 
29 
29 
30 
34  37 
41 
44 
45 
48 
52 
ELECTRICAL  EQUIPMENT 
- FAULT TRACING 
-Introduction 
-Charging systcm 
-Ignition system 
-Starter system  54 
55 
-. _, 
56 
60 
IS6 I CIRCUIT DIAGRAMS 
-Four  cylinder  petrol engine 
-2.25 litre  diesel  engine 
-2.5 litre  diesel  engine 
- V8 cylinder  engine 
-Composite  circuit diagram - 1986 onwards  all models 
- Dim-dip  circuit diagram 
-Twin Tank - Twin  pumps 
-Optional  equipment  circuit diagrams  64 
66 
68 
70  72 
74 
75 
76 
II  
						

							- . .. .aI 
I. 
Special Service Tools 
The use of approved  special service  tools is important.  They are essential if servicc 
operations  are to be  carried  out efficiently, and  safely. The amount  of time  which  they 
save can  be considerable. 
Every  special  tool is designed  with the close  co
-operation  of Land  Rover  Ltd., and no 
tool is put into production  which has not been tested  and approved  by us. New tools are 
only  introduced  where 
an operation  cannot  be  satisfactorily  carried out using existing 
tools 
or standard equipment. Thc user is  therefore  assured that the tool  is necessary  and 
that  it will  perform accurately,  efficiently and safely. 
Special  tools bulletins  will be issued  periodically  giving details 
of new tools  as they are 
introduced. 
A11 orders  and enquiries  from the Unitcd Kingdom  should be sent  direct  to  V. L. 
Churchill.  Overseas  orders should  be placed  with the local V. L. Churchill  distributor, 
where  one 
exists. Countries  where there is no distributor  may order  direct  from V. L. 
Churchill  Limited, 
PO Box 3 Daventry, Northants,  England 11 4NF. 
The tools  recommended in this Workshop  Manual are listed  in a multi-language, illustraicd catalogue 
obtainable  from 
Messers. V. L. Churchill  at  the above  address under  publication number 2217/2/84 or from 
Land  Rovcr  Ltd., under  part  number 
LSM0052TC from the following address, Land  Rovcr  Merchandising 
Scrvice, P.O. Box 534, Erdington, Birmingham B24 OQS. 
V