Land Rover Defender Workshop 1993 Rover Manual

							BODY 
Refit REAR DOOR TRIM CASING 
Service repair no - 76.34.09 
Remove 
12.  With  assistance, position  rear headlining to roof 
and locate  rear corners in  cant rail. 
13.  Push headlining  rearwards and position  over 
rear  end lining  mounting brackets. 
14.  Locate  front corners  of headlining  in cant  rail. 
15.  Position front  edge of rear headlining  over front 
headlining  and secure  with trim studs. 
16.  Adjust rear  headlining to achieve  good fit at  all 
corners. 
17.  Fit  rear  interior lamp. See Electrical. 
18.  Fit interior  roll
-over bar. See this Section  . 
19.  Fit rear end  lining. See this  Section  . 
20.  Fit rear  grab  handles.  See this Section.  1. 
Unscrew  2 bolts  and remove  grab handle from 
2.  Remove  2 screws and detach  wiper motor cover. 
3.  Remove  7 screws  securing  trim casing  to door. 
4.  Remove  two screws and  lift wiper  motor  harness 
5.  Carefully  release 8 clips  securing trim  casing to 
6.  Remove trim  casing and collect door lock cover. 
rear door. 
cover from harness support bracket. 
door. 
21.  Fit side 
trim panels.  See this  Section. 
22. 
Fit rear end  trim  panels.  See this Section. 
Refit 
7. Position  door lock cover,  fit trim  casing  and 
secure  with clips. 
8.  Fit harness cover  and secure with two screws. 
9.  Secure  door panel with  retaining screws. 
10.  Position  wiper motor cover and  secure with 2 
11.  Position  grab handle and secure with  2 bolts. 
screws. 
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							BODY 
4. Remove sun roof. 
5.  Starting  from centre  rear,  peel headlining finisher 
from  inner  frame. 
6. Remove  18 screws  securing  inner frame  to outer 
frame and detach  inner frame. 
7. Lift outer frame from roof. 
SUN ROOF 
Service  repair no - 76.82.15 
Remove 
NOTE: Assistance  may be required  to remove  the 
sun  roof  assembly. 1. Open  sun roof  fully. 
2. Disengage  spring lock  from operating handle 
catch. 
3.  Holding sun  roof at both sides,  release hinges 
from  locating brackets at  front of outer frame. 
12. Starting from  centre rear, fit headlining finisher 
13.  Press  finisher firmly over  inner frame  and 
continue around complete frame,  ensuring 
finisher  lies flat on headlining. 
14.  Fit sun  roof hinges fully  into locating  brackets on 
outer frame,  and lower  the glass  panel. 
15.  Engage  operating handle  catch with spring lock 
of  outer  frame and  close sunroof. 
Refit lip into  locating channel  of inner  frame. 
8.  Clean  roof area around  outer frame seating. 
9.  Position  outer frame on  roof. 
10.  Fit inner frame  to headlining and  secure to outer 
frame  with 18 screws  but do not  fully  tighten. 
11  . Check alignment  of inner  and outer  frames  with 
roof mounting  and headlining, adjust  as 
necessary,  and fully  tighten fixing screws  to 10 
Nm  (7 Ibf.ft). 
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							BODY 
5. Remove caps and unscrew  front seat belt fixing 
bolts  from B/C  posts. 
6. Carefully  prise side trim panel  cap fastener  from 
B/C  posts. 
7. Carefully  prise 2 trim studs,  from both sides, 
securing  headlining  to body  at door  aperture. 
8. Carefully  prise out 5 trim studs  securing  front 
and  rear  headlinings  to roof. 
9.  From  both sides,  pull side  trim panel  inwards 
FRONT  HEADLINING 
Service  repair no 
- 76.64.10 
Remove 
1. Remove  sun roof  headlining  finisher. 
2.  Remove  sun visors.  See this  Section. 
3. Remove  interior lamp. See Electrical. 
4.  Remove  4 retaining  screws and detach  both 
A 
enough  to release  rear corners  of front 
10. Lower  headlining  and remove  from vehicle. 
NOTE:  Take care not to bend  the headlining  on 
removal  and refitting. 
post trims. 
15. Fit side  trim trim studs  at ‘B/C’  posts. 
16.  Secure seat  belts to 
B/C posts  and tighten  bolts 
to 
32 Nm  (24 lbf.ft).  Fit caps  to bolts. 
17. Fit A post  trims. 
18.  Fit interior  lamp. See Electrical, 
19.  Fit sun  visors.  See this  Section 
. 
20. Fit sun  roof  headlining  finisher. 
Refit 
11. With  assistance,  raise headlining  to roof. 
12. Carefully  pull side  trim panel  inwards,  on both 
sides,  and slide  headlining  behind trim panel. 
13.  Position  front headlining  into recess  of rear 
headlining  and secure  both to roof  mounting 
brackets  with 
5 trim studs. 
14.  Secure  both sides  of front  headlining  to body  at 
door  apertures  with trim studs. 
11 
headlining.  
						

							BODY 
INTERIOR REAR VIEW MIRROR SUN VISORS 
Service repair no - 76.10.51 
Remove  Remove 
Service 
repair no - 76.10.17. 
1. Remove  retaining  screw securing mirror 
2. Slide adjustment arm up from mounting  slug and 
1. Raise sun visor. 
2. Remove 2 screws and  collect sun visor. 
adjustment  ann to mounting slug. 
remove  rear view mirror. 
J6053 2 
Ref it 
3. Position  sun visor  and secure with 2 screws. 
Refit 
3. Slide  mirror  adjustment  arm  over mounting  slug. 
4.  Secure  mirror with retaining  screw. 
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							BODY 
base. 
3.  Prise  seat belt retaining clip  from side 
of seat 
mounting and remove trim  studs. 
4.  Unscrew  bolt and remove  seat belt inertia reel 
from  roll
-over bar mounting bracket. 
5. Remove seat  belt and  inertia reel  assembly. 
6. Unscrew bolt and  washer  and  remove seat  belt 
buckle  stalk from roll
-over mounting bracket. 
7. On the  drivers side,  disconnect harness plug 
connector of audible  warning circuit at buckle 
stalk. 
FRONT SEAT BELTS 
Service  repair no - 76.73.13 
Remove 
1.  Remove  cap and  unscrew  seat  belt  guide 
bracket  fixing bolt from  B/C post. 
2.  Remove  3 bolts  and plain  washers  securing  seat 
belt mounting  bracket to  body  on outside 
of seat 
11. Secure seat  belt bracket  to floor  on outside  of 
seat base and  tighten bolts to 23  Nm  (17 Ibf.ft). 
12. Fit seat  belt retaining clip to side  of seat  base 
and  secure  with trim  studs. 
13.  Extend  belt from  inertia  reel, secure  slide bracket 
to 
B/C post and tighten bolt  to 32  Nm  (24 Ibf.ft). 
14.  Refit fixing  bolt cap. 
Refit 
8. Reconnect  harness plug  of audible  warning 
circuit. 
9.  Position stalk  on roll
-over  bar mounting bracket 
and  tighten  fixing bolt to  32 Nm  (24 Ibf.ft). 
10.  Secure  seat belt inertia reel  to roll
-over  bar 
mounting and tighten bolt to  32 Nm  (24 Ibf.ft). 
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							BODY 
3. Remove two torx bolts, from both sides,  securing 
top  bar 
to roof  mounting. 
4. Slide  top bars  rearwards to disengage  from main 
roll
-over  bar assembly. 
5. Lift main  roll-over bar assembly  from vehicle 
6. If necessary,  remove 2 torx bolts and nuts,  from 
both  sides,  and detach  lower cross  bar from 
main  roll
-over bar. 
EXTERIOR  ROLL-OVER BAR 
Service repair no - 76.11.39 
Remove 
1. Remove  tom bolt,  from  both sides,  securing  top 
of  roll
-over  bar to roof mounted  bar. 
2. With assistance to support  roll-over bar at 
windscreen,  remove 
4 torx bolts,  from both 
sides,  securing  roll
-over bar to fender  mounting. 
10. Slide 
top bars  into main  roll-over  bar, position  on 
roof  mounting  and secure  with 
torx bolts to 25 
Nm  (18 Ibf.ft) 
11 
. Secure  roll-over bar to both fender  mountings 
with 
torx bolts,  Tighten  to 25 Nm (18 Ibf.ft). 
12.  Secure  top bars 
to main  roll-over bar and  tighten 
fixing  bolts 
to 25 Nm (18 lbf.ft). 
Refit 
7. Locate  lower cross  bar into  main  roll-over bar 
mounting  brackets and secure  with 
torx bolts and 
nuts  to 
25 Nm (18 Ibf.ft). 
roll
-over  bar mounting  brackets. 
position  on fenders. 
8. Ensure  rubber gaskets  are fitted  correctly to 
9. With assistance,  lift roll-over  bar assembly  and 
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							BODY 
2. Remove 4 bolts and spring washers securing 
tow  bar centre  mounting  bracket 
to chassis. 
3. Remove both bolts securing  the two  tow  bar 
locating  tubes in rear chassis  cross member. 
4. Remove 2 bolts securing  tow bar top  mounting 
brackets  to chassis. 
5. With assistance,  withdraw tow bar assembly 
from chassis. 
REAR TOW BAR 
Service  repair no 
- 76.11.41 
Remove 
1. Remove bolt,  washer and nut from  both sides, 
securing  tow bar lower mounting brackets and 
towing eyes  to chassis. 
9. Secure tow  bar centre mounting bracket to 
Refit underside of chassis and tighten bolts to 25 Nm 
(18 Ibf.ft). 
10.  Position  towing eyes  to lower mounting  brackets 
and secure 
to chassis  and tighten bolts to 25 Nm 
(18 Ibf.ft). 
11. Fully  tighten  tow bar top mounting bracket  bolts 
to 
25 Nm  (18 Ibf.ft). 
6. With  assistance,  lift the  tow  bar assembly and 
locate both  tubes 
in the chassis crossmember. 
7. Secure top  tow bar mounting brackets  to chassis 
but do  not fully tighten  fixings. 
8.  Secure  tow bar locating  tubes 
to rear of chassis 
and  tighten bolts to 
25 Nm (18 Ibf.ft). 
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							ELECTRICAL 
REAR WIPER MOTOR Refit 
Service repair no - 84.35.12 
Remove 
8. Locate  wiper motor  drive spindle  through 
9. Position  wiper motor  mounting  bracket and 
aperture 
in rear  door. 
secure  to rear  door.  Tighten  bolt to 
23 Nm (17 
Ibf.ft). 
10.  Reconnect  harness multi
-plug. 
11.  Secure  drive spindle  to door. 
12.  Fit wiper  motor  cover. 
13.  Fit rear  wiper  arm. 
1. 
With  assistance,  unscrew 3 retaining  nuts and 
remove  spare wheel  from rear door  mounting 
studs. 
nut. 
(96 Ibf.ft). 3. Remove  nut and  withdraw  wiper arm from  drive 
spindle. 
4. Remove  retaining  nut, plain  washer  and rubber 
washer  securing  wiper motor  drive spindle  to 
door. 
5. Remove two screws  and remove  cover from 
wiper  motor  mounting  bracket. 
6. Disconnect  wiper motor  harness  multi-plug. 
7. Remove  bolt, with  rubber  washer,  and detach 
wiper  motor,  complete  with mounting  bracket, 
from  rear door. 
2. 
Lift  wiper  arm end cap to gain  access  to securing 
14. Fit spare  wheel.  Tighten  retaining  nuts to 130Nm 
1  
						

							ELECTRICAL 
SWITCH PANEL-REAR DOOR SERVICES Refit 
Service repair no - 86.65.78 
Remove 
5. Feed harness  into switch  panel and reconnect 
6. Position  switch panel on fascia  and secure  with 
switch 
multi
- plugs. 
trim  studs. 
1. Carefully  prise out 4 trim studs  securing  switch 
panel 
to centre  of fascia. 
2. Withdraw  switch panel and disconnect 
multi
-plugs  from the three  switches. 
3.  Pull  harness  multi
-plugs through  aperture  in 
base  of panel. 
2  
						

							ELECTRICAL 
SWITCHES - TAILGATE  FUNCTIONS  INTERIOR LAMP 
Service  repair no 
- 84.35.33  Rear wiper switch 
Service repair  no 
- 84.30.27 Rear wash  switch 
Service repair  no 
- 86.65.36 Heated rear screen 
switch 
and  roof  mounting  bracket. 
Remove harness plug. 
Service  repair no - 86.45.02 
Remove 
1. Carefully  prise lens cover  from lamp  unit. 
2.  Remove 
2 nuts  securing  lamp unit to headlining 
3. Release  lamp from bracket  studs and disconnect 
1. Carefully  prise out 4 trim studs  securing  rear 
door  services  switch panel to centre  of fascia. 
2. Withdraw  switch panel from fascia  and 
disconnect  multi
-plug from  rear wiper  switch. 
3. Press  in switch  retaining  lugs and push  switch 
through  panel aperture. 
4. Remove  rear wiper  switch. 
4. Remove  interior lamp. 
5. Connect  harness plug and locate  lamp unit. 
Ensure  lamp switch  eyelet is correctly  seated on 
lamp  unit base. 
6. Secure  lamp unit to mounting  bracket with 2 nuts 
and  refit  lamp  lens. 
Refit 
Refit 
5. Position  switch, reconnect  multi-plug and refit 
rear  door  services  switch panel 
3