Land Rover Defender Workshop Rover Manual

							CHASSISANDBODY
15
REPAIR
Refit
8. Insert glassintorunners atan angle as
illustrated.
9. Whilst liftingglass, position itsquarely in
runners, raisetotop oftravel andinsert timber
support.
10. Secure hingesiderunner withsingle screw
ensuring thatpacking stripisin position.
11. Locate packing stripandsecure opposite runner
with 2screws. Ensurethatall3screw heads are
well below bottom ofrunners toprevent damage
to glass.
12. Locate regulator inwindow liftchannels.
13. Fitmounting panel
SeeMounting panel-front
door
. LOCKING
BARREL-FRONT DOOR
Service repairno-76.37.39
Remove 1. Remove doortrimcasing
See Door trim
casing
and plastic sheet.
2. Remove mounting panel
SeeMounting panel
- front panel
.
3.Raise andsupport glasstogain access tolatch
mechanism.
4. Release springclipand disconnect rodfrom lock
operating lever.
5. Remove singlescrewandwithdraw locklever
assembly.
6. Withdraw lockbarrel fromexterior doorhandle
complete withlocking sleeve.     
						

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16 REPAIR
7.
To remove barrelfromplastic retaining sleeve,
depess springloaded buttonandwithdraw
sleeve.
Refit
NOTE: Ifanew barrel isbeing fitted, check
that number onbarrel coincides with
number onaccompanying key.
8.Push plastic retaining sleeveoverbarrel until
spring loaded peglocks itinto position.
9. Fitbarrel andplastic sleeve assembly tolocking
sleeve andinsert intoexterior handlereversing
instruction 6.
10. Assemble locklever components asillustrated
and from inside ofdoor panel, fitthem tobarrel
assembly withsingle screw.
11. Connect operating rodtolock lever andsecure
with spring clip,reversing instruction 4.
12. Fitmounting panel
SeeMounting panel-front
door
. DOOR
STRIKER -ADJUST
Service repairno-76.37.23 -front door
Service repairno-76.37.24 -rear door, 110/130
Adjust
1. Loosen 2Torq bolts securing strikertobody.
2. Adjust alignment ofstriker vertically and
horizontally, lightlytighten bolts.
3. Close door,check forcorrect latching withdoor
lock andforcentering onstriker.
4. Add orremove packing shimsasnecessary
behind strikerandfully tighten bolts.
5. Carry outfurther adjustment asnecessary. Iffull
adjustment isnot achieved carryoutthe
following:
6. Remove strikerandnutplate.
7. Elongate strikerboltholes inB orC post in
direction required.
8. Refit striker andadjust asnecessary.    
						

							CHASSISANDBODY
17
REPAIR
REAR
SEATCUSHION -90
Service repairno-78.10.18/99
Remove
1. Release seatcushion stowage strap.
2. Remove 4bolts andspring washers andliftseat
cushion frompivot brackets.
3. Remove 4bolts, plainwashers, springwashers
and nuts. Detach bothpivot brackets fromwheel
arch.
Refit 4. Secure pivotbrackets towheel archandtighten
bolts to
10Nm (7lbf/ft).
5. Position seatcushion inpivot brackets and
secure with4bolts andspring washers.
6. Fitstowage strap. REAR
SEATSQUAB -90
Service repairno-78.10.58/99
Remove 1. Release seatcushion stowage strapandlower
seat cushion.
2.Slacken 2bolts securing seatsquab brackets to
body side.
3. Remove 2bolts, plainwashers, springwashers
and nuts securing seatsquab towheel arch.
4. Lift seat squab andrelease brackets from
retaining bolts.
Refit 5. Lower seatsquab brackets overretaining bolts,
tighten boltsto
10Nm (7lbf/ft).
6. Secure seatsquab towheel arch,tighten boltsto
10Nm (7lbf/ft).
7. Raise seatcushion andfitstowage strap.    
						

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18 REPAIR
REAR
BENCH SEAT
Service repairno-78.10.57/99
Remove
1. Remove rearbench seatcushion.
2. Remove 4bolts securing seatframe tobody and
collect spacers andbrackets containing captive
nuts.
3. Remove screwsecuring rearendofsquab to
body.
4. Remove rearbench seat. Refit
5. Position rearbench seattobody.
6. Position bracketandspacers, andloosely fit
bolts securing frontendofcushion frameto
body.
7. Loosely fitbolts securing rearendofcushion
frame tobody while second personholds
bracket inposition fromunder vehicle.
8. Fitscrew securing squabtobody.Tighten to
10
Nm (7lbf/ft).
9. Tighten cushion frametobody boltsto10Nm (7
lbf/ft).
10. Fitbench seatcushion.  
						

							CHASSISANDBODY
19
REPAIR
FRONT
SEATBELTS
Service repairno-76.73.13
Remove
1. Remove plasticseatbeltguide fromsideoffront
seat base.
2. Remove seatbeltlower anchorage bolt.
3.Remove plasticcapfrom upper beltguide bolt.
4. Remove boltsecuring beltguide toB post.
5. Move rearcarpet asideandremove bolt
securing inertiareeltobase ofB post.
6. Remove seatbuckle stalkanchorage boltat
inside rearoffront seat.
Refit
NOTE: Tighten allseat beltanchorage
bolts to
32Nm (24lbf/ft).
7.Fitseat buckle stalktomounting atrear offront
seat.
8. Position inertiareeltobase ofB post and
secure withbolt.
9. Reposition carpet.
10. Fitupper guidetoB post.
11. Fitplastic captoguide bolt.
12. Fitseat belttoseat base lower anchorage
bracket.
13. Fitplastic seatbeltguide toseat base.      
						

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20 REPAIR
REAR
SEATBELTS -90/110 STATION WAGON,
INWARD FACINGSEATS
Service repairno-76.73.18
Remove
1. Release beltstraps frombuckles.
2. Release stowage strapsandlower bothseat
cushions.
3. Unscrew boltsecuring lapstrap tobody
mounting.
4. Remove lapstrap, wavywasher, spacerand
plain washer.
5. Repeat operation forbuckle strap.
Refit 6. Secure lapstrap andbuckle strapstobody.
Tighten boltsto
32Nm (24lbf/ft).
7.Ifrequired, secureseatcushions andbelts in
stowed position. REAR
SEATBELTS -110
Service repairno-76.73.18
Remove 1. Remove rearinward facingseats
SeeRear
seat squab -90
orSee Rear bench seat.
2. Remove sidetrimpanel
See Side trimpanel.
3.Remove boltsecuring seatbeltinertia reeltoC
post.
4. Remove seatbeltassembly.
5.Pull seat beltstraps between seatcushion and
squab intorear ofvehicle.
6. Remove finishercapand boltsecuring seatbelt
anchorage tofloor.
7. Remove seatbeltassembly.    
						

							CHASSISANDBODY
21
REPAIR
Refit
8. Secure seatbeltstraps tofloor mounting.
Tighten boltto
32Nm (24lbf/ft)and fitfinisher
cap.
9. Feed beltstraps between seatcushion and
squab.
10. Fitinertia reeltoC post. Tighten boltto
32Nm
(24 lbf/ft).
11. Fitside trimpanelSee Side trimpanel.
12. Fitrear inward facingseats
SeeRear seat
squab -90
orSee Rear bench seat. SIDE
TRIM PANEL -90 STATION WAGON
Service repairno-76.13.70
Remove 1. Remove rearseat squabs
See Rear seat
squab
.
2. Remove rearendtrimpanel
See Rear end
trim panel
.
3.Prise capfrom frontseatbeltupper guide
retaining bolt.
4. Unscrew retainingboltand remove seatbelt
from Bpost.
5. Carefully prisetrimstud from Bpost.
6. Remove 4bolts securing sidetrimpanel tobody
side.
7. Release topedge ofside trimpanel bystriking
upwards withthehand todisengage 3spring
clips.
8. Lift trim panel fromwindow surround andremove
from vehicle.   
						

							76CHASSIS
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22 REPAIR
Refit
9. Fitnew spring clipstothe 3brackets ontop
edge ofside trimpanel.
10. Align trimpanel, ensuring itis correctly
positioned aroundsidewindow.
11. Locate trimpanel spring clipsoninner cantrail
and press firmlydown tosecure topedge oftrim
panel.
12. Align bosses oftrim panel withbody sidefixing
holes andsecure with4bolts andwashers. Do
not fully tighten atthis stage.
13. Fittrim stud tosecure bottom edgeoftrim panel
to B post.
14. Secure seatbeltguide toB post, tighten boltto
32Nm (24lbf/ft)and fitcap.
15. Fitrear endtrimpanel
See Rear endtrim
panel
.
16. Fitrear seat squab
See Rear seatsquab. SIDE
TRIM PANEL -110 STATION WAGON
Service repairno-76.13.70
Remove 1. Remove rearinward facingseats
SeeRear
seat squab -90
,o rSee Rear bench seat.
2. Remove rearendtrimpanel
See Rear end
trim panel
.
3.Prise finisher capfrom rearseat beltupper guide
bracket retaining bolt.
4. Unscrew boltand remove guidebracket fromC
post.
5. Remove boltsecuring seatbelttowheel arch
mounting.
6. Prise trimpanel capfastener fromCpost.
7. Remove seatbeltaperture finisherfromsidetrim
panel.
8. Remove screwandrelease seatbeltclipfrom C
post.   
						

							CHASSISANDBODY
23
REPAIR
9.
Remove fixingssecuring bottomedgeoftrim
panel tobody side.
10. Release topedge oftrim panel bystriking
upwards withthehand todisengage 3spring
clips.
11. Lifttrim panel fromwindow surround andfeed
seat beltthrough panelaperture.
12. Remove trimpanel fromvehicle.
Refit 13. Fitnew spring clipstothe 3brackets ontop
edge ofside trimpanel.
14. Feed seatbeltthrough aperture intrim panel and
fit finisher.
15. Align trimpanel, ensuring itis correctly
positioned aroundsidewindow.
16. Locate trimpanel spring clipsoninner cantrail
and press firmlydown tosecure topedge oftrim
panel.
17. Align bosses oftrim panel withbody sidefixing
holes andsecure withbolts orscrews. If
individual typeseats arefitted donot fully tighten
fixings atthis stage.
18. Fitseat beltcliptoC post.
19. Fittrim panel capfastener toC post.
20. Fitseat belttowheel arch.Tighten boltto
32Nm
(24 lbf/ft).
21. Fitseat beltguide bracket toC post. Tighten
bolt to
32Nm (24lbf/ft)and fitfinisher cap.
22. Fitrear endtrimpanel
See Rear endtrim
panel
.
23. Fitinward facingseats
SeeRear seatsquab,
or
See Rear bench seat. REAR
ENDTRIM PANEL -90/110 STATION
WAGON Service repairno-76.13.71
Remove
1. Pull edge ofrear endtrimpanel firmlytorelease
2 spring retaining clipsfromvertical railatdoor
aperture.
2. Remove rearendtrimpanel.
Refit 3. Fitnew spring clipstothe 2brackets onside of
trim panel.
4. Position outboard edgeoftrim panel incorner to
abut sidetrimpanel andlocate spring clipson
vertical rail.
5. Press edgeoftrim panel firmlytosecure in
position.    
						

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CUBBY
BOX-90/110 STATION WAGON
Service repairno-76.25.04
Remove 1. Remove radio/cassette player,iffitted.
2. Open cubby boxlidand remove 2caps
concealing fixingbolts.
3. Remove fixingboltsandwashers.
4. Remove 2screws andliftcup holder fromcubby
box.
5. Unscrew 2bolts securing frontofcubby boxto
floor mounting.
6. Lift cubby boxand, ifapplicable, release
radio/cassette playerleads.
7. Iffitted, disconnect multi-plugfromEGR control
unit, located onbase ofcubby box.
8. Remove cubbybox.
Refit 9. Position cubbyboxtomounting and,if
applicable, insertradio/ cassette playerleads.
10. Secure frontofcubby boxtofloor andfitcup
holder.
11. Open cubby boxlid,secure inposition, andfit
bolt caps.
12. Fitradio/cassette player,iffitted. REAR
GRAB HANDLE -90/110 STATION WAGON
Service repairno-76.58.35
Remove
1. Carefully prisetopand bottom edgesoffinisher
caps fromgrab handle andthen hinge outwards
to gain access tofixing screws.
2. Remove 4fixing screws anddetach grabhandle
from rearendtrimpanel.
Refit 3. Position grabhandle onrear endtrimpanel and
secure with4fixing screws.
4. Press finisher capsoverscrews.