Land Rover Defender Workshop Rover Manual
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CHASSISANDBODY 5 REPAIR SILL LOCKING BUTTON-REAR SIDEDOOR Service repairno-76.37.30 Remove 1. Remove doortrimcasing See Door trimcasing . 2. Peel back sufficient ofplastic sheettoreveal mechanism. 3. Release springclipsecuring buttontooperating rod and withdraw rodfrom button. 4. Remove 2screws securing buttontodoor panel and remove button. Refit 5. Secure lockingbuttonassembly todoor panel with 2screws. 6. Fitoperating rodtobutton assembly andsecure with spring clip. 7. Re-seal plasticsheetandfitdoor trimcasing See Door trimcasing. REMOTE CONTROL LEVER-REAR SIDEDOOR Service repairno-76.37.32 Remove 1. Remove doortrimcasing See Door trimcasing . 2. Peel-back sufficientofplastic sheettogain access toremote lever. 3.Remove springclipand disconnect controlrod from locking button. 4. Release springclipand disconnect shortlocking button control rodfrom latch mechanism. 5. Disconnect longremote controlrodfrom latch assembly.
76CHASSIS ANDBODY 6 REPAIR 6. Remove 2screws securing remotecontrollever to mounting panel. 7. Release controlrodsfrom plastic retaining clips located inmounting panel. 8. Withdraw remotecontrolleverandrods from door. Refit 9. Fitplastic retaining clipstorod assembly into position andsecure with2screws. 10. Connect controlrodstolatch assembly and secure withclips. 11. Fitplastic retaining rodclips tomounting panel. 12. Connect controlrodtolocking buttonandsecure with clip. 13. Re-seal plasticsheetandfitdoor trimcasing See Door trimcasing. DOOR LATCH -REAR SIDEDOOR Service repairno-76.37.13. Remove 1. Remove doortrimcasing See Door trim casing . 2. Peel-back sufficientofplastic sheettoreveal latch. 3. Release remotecontrolleverrodfrom latch assembly. 4. Disconnect doorouter handle controlrodfrom latch assembly. 5. Disconnect doorlocking buttonremote control rod from latch mechanism. 6. Remove 3retaining screwsandwithdraw latch assembly fromdoor. Refit 7. Fitlatch assembly todoor andsecure with3 screws, notingthatuppermost screwislonger. 8. Connect remotecontrolleverstolatch mechanism reversinginstructions 3,4and 5. 9. Re-seal plasticsheetandfitdoor trimcasing See Door trimcasing.
CHASSISANDBODY 7 REPAIR DOOR GLASS -REAR SIDEDOOR Service repairno-76.31.02 Remove 1. Disconnect doorcheck rodfrom door post. 2. Remove doortrimcasing See Door trimcasing . 3. Remove plasticsheet. 4. Remove windowregulator assembly See Window regulator -rear side door . 5. Disconnect andremove doorsilllocking button SeeSilllocking button. 6.Disconnect controlrodsfrom latch anddoor outer handle mechanism. 7. Remove 4screws retaining mounting panelto door andremove panel,complete withrods and control lever. 8. Remove singleselftapping screwtoremove water channel. 9. Remove 2screws andremove doorcheck torsion bar. 10. Remove doorcheck rodbybending backend stop toenable rodtobe withdrawn.
76CHASSIS ANDBODY 8 REPAIR 11. Remove 2self-tapping screwsfromeach side and remove glasslower channels. 12. Remove innerandouter weather stripsfrom door sill. 13.Lower glassdown tobottom ofdoor, liftglass over lower edgeandwithdraw fromdoor. 14. Remove liftchannel fromglass, ifnecessary. Refit 15. Fitliftchannel tonew glass, ifnecessary. 16. Insert glassintolower channels andcarefully push glass uptotop offrame. 17. Secure lowerchannels with4self-tapping screws. Ensurethatscrew heads arescrewed down firmlybelow bottom ofchannels toprevent damage toglass. 18. Fitdoor check rodand bend endstop back to closed position. 19. Fitcheck stoptorsion barand secure with2nuts and bolts. 20. Fitwater channel andsecure withsingle self-tapping screw. 21. Fitmounting panelcomplete withrods and remote controllever. 22. Connect controlrodstolatch anddoor outer handle mechanism. 23. Fitdoor silllocking buttonandconnect control rod See Silllocking button. 24. Fitwindow regulator SeeWindow regulator. 25. Fitdoor inner andouter sillwear strips. 26. Fitand re-seal plasticsheet. 27. Fitdoor trimcasing See Door trimcasing. 28. Connect doorcheck rodtodoor post.
CHASSISANDBODY 9 REPAIR MOUNTING PANEL-FRONT DOOR Service repairno-76.11.28 Remove 1. Remove doortrimcasing See Door trim casing and plastic sheet. 2.Remove 4screws securing windowregulator to mounting panel. 3. Remove 5screws securing mounting panelto door frame. 4. Release remotecontrolleverrodfrom latch mechanism andfrom plastic clipinmounting panel. 5. Slide window regulator armfrom mounting panel channel andremove panelwithremote control lever androd. Refit 6. Engage windowregulator arminmounting panel channel. 7. Connect remotecontrolrodtolatch mechanism and secure withclip. 8. Fitmounting panelandretain with5screws. 9. Secure window regulator tomounting panelwith 4 screws. 10. Raise andlower window tocheck forfree movement. 11. Fitplastic sheet,anddoor trimcasing See Door trimcasing .
76CHASSIS ANDBODY 10 REPAIR SILL LOCKING BUTTON-FRONT DOOR Service repairno-76.37.29 Remove 1. Remove doortrimcasing See Door trim casing . 2. Peel back sufficient ofplastic sheettoexpose mechanism. 3. Release springclipand disconnect operatingrod from latch mechanism. 4. Remove 2screws andwithdraw lockingbutton assembly. Refit 5. Secure lockingbuttonassembly todoor with2 screws. 6. Connect operating rodtolatch mechanism and secure withspring clip. 7. Re-seal plasticsheetandfitdoor trimcasing See Door trimcasing. WINDOW REGULATOR -FRONT DOOR Service repairno-76.31.45 Remove 1. Remove doortrimcasing See Door trimcasing . 2. Remove plasticsheet. 3. Temporarily fithandle, position windowhalfopen and support withalength oftimber. 4. Remove 2lower screws securing mounting panel todoor andslacken 3upper screws. 5. Remove 4screws retaining windowregulator to mounting panelandslide operating armsfrom channels attachedtoglass andmounting panel and remove regulator. Refit 6. Insert regulator operating armsintochannels. 7. Fitand tighten mounting panellowerscrews and tighten upperscrews. 8. Position holesinregulator toline-up withholes in mounting panelandsecure with4screws. 9. Temporarily fitregulator handleandcheck that glass canberaised andlowered withouttight spots. 10. Secure plasticsheet. 11. Fitdoor trimcasing See Door trimcasing.
CHASSISANDBODY 11 REPAIR REMOTE CONTROL LEVER-FRONT DOOR Service repairno-76.37.31 Remove 1. Remove doortrimcasing See Door trim casing . 2. Peel back sufficient ofplastic sheettogain access toremote lever. 3.Release springclipand disconnect controlrod from latch mechanism. 4. Release controlrodfrom plastic clipinmounting panel. 5. Remove 2screws securing remotecontrollever to mounting panelandwithdraw leverand control rod. Refit 6. Feed control rodinto position andloosely secure lever tomounting panelwith2screws. 7. Connect controlrodtolatch mechanism and secure withspring clip. 8. Tighten controlleverretaining screws. 9. Secure controlrodtoplastic clipinmounting panel. 10. Secure plasticsheet. 11. Fitdoor trimcasing See Door trimcasing.
76CHASSIS ANDBODY 12 REPAIR EXTERIOR HANDLE-FRONT DOOR Service repairno-76.58.01 Remove 1. Remove doortrimcasing See Door trim casing . 2. Remove mounting panel SeeMounting panel - front door andsupport glasswithtimber. 3.Disconnect operatingrodfrom handle mechanism. 4. Disconnect rodfrom locking barrellever. 5.Remove 2screws andwithdraw handle assembly. Refit 6. Fithandle todoor ensuring thattwobezels arein position -flat faces towards door,andsecure with 2screws. 7. Connect rodtohandle operating leverand secure withspring clip. 8. Connect rodtolocking barrelleverandretain with spring clip. 9. Fitmounting panel SeeMounting panel-front door .
CHASSISANDBODY 13 REPAIR LATCH ASSEMBLY -FRONT DOOR Service repairno-76.37.12 Remove 1. Remove mounting panelSeeMounting panel andsupport glasswithtimber. 2. Disconnect controlrodfrom handle operating lever. 3. Disconnect controlrodfrom locking leveron handle. 4. Disconnect lockingbuttoncontrol rodfrom latch mechanism. 5. Remove 2screws andremove handleassembly from door. 6. Remove 2self-tapping screwsretaining lower end ofwindow glassrunner. 7. Remove 3screws securing latchassembly to door. 8. Whilst takingcarenottodamage runner,ease runner awayfromlatch andmanoeuvre latch assembly fromdoor. Refit 9. Carefully easewindow runneraway,sufficiently to enable latchtobe located intoposition. 10. Secure latchtodoor with3screws. 11. Secure window runnerwith2screws ensuring that packing stripisin position andthatscrew heads arebelow bottom ofrunner toprevent damage toglass. 12. Fithandle with2screws, ensuring thatbezels are inposition. 13. Connect controlrodtohandle operating lever and secure withspring clip. 14. Connect controlrodtolocking leverandretain with spring clip. 15. Connect lockingbuttoncontrol rodtolatch lever and secure withspring clip. 16. Fitmounting panel SeeMounting panel.
76CHASSIS ANDBODY 14 REPAIR DOOR GLASS -FRONT DOOR Service repairno-76.31.01 Remove 1. Remove mounting panel SeeMounting panel - front door . 2. Remove windowregulator. 3. Push glass uptotop ofits travel andsupport with asuitable lengthoftimber. 4. Remove 2self tapping screwssecuring window glass runner onlatch sideofdoor andsingle screw fromhinge side. 5.Taking carenottodamage paint,priseexterior waist weather stripfrom door. 6. Remove timbersupport andlower glassto bottom ofdoor. 7. Ease runner fromglass athinge sideofdoor, lift glass overbottom edgeofdoor andwithdraw.