Land Rover Defender Workshop 1993 Rover Manual

							CHASSIS AND BODY 
DEFENDER 90 
4 REVISED: OCT 1993  
						

							CHASSIS AND BODY 
DEFENDER 
90 
CHASSIS  ALIGNMENT  DIMENSIONS 
A - Front Datum 
B - Chassis  Datum 
C - Front axle centre  line 
D 
- Rear  axle centre  line 
1. 239,00 - 236,50 mm 20.  519,60 - 517,00 mm 
2. 82,00 - 79,50mm  21. 
259,80 - 258,50 mm 
3. 633,00  mm  22. 
1242,60 - 1240,60 mm 
4. 2420,60 - 2418,60  23. 
642,50 - 639,50 mm 
5. 2306,40 - 2305,40 mm 24. 750,90 mm 
6. 981,20 - 978,70 mm 25.  439,50 - 436,50 mm 
7.  182,70  26. 
136,50 
mm 
8. 41,50 - 37,00 mm 27. 299,50 - 295,50 mm 
9. 252,00 - 250,00  mm  28. 
103,00 - 100,00 mm 
10. 110,00 mm  29. 131,50 - 126,50 mm 
11. 2360,00  mm - wheelbase  30. 705,50 - 704,50 mm 
12.  636,00 
- 654,00 mm 31.  705,50 - 704,50 mm 
13. 488 - 483 mm 32.  42,20 - 40,20 mm 
14. 488 - 483 mm  33. 491,00 - 486,00 mm 
15.  3431,10 
- 3426,10  mm  34. 594,20 - 593,40 mm 
16.  588,30 
- 586,30 mm 35. 283,00 - 282,20  mm 
17.  2313,80 
- 2311,80  mm  36. 32,25 - 31,25 mm 
18.  590,50  mm  37. 397,00 
- 395,00 mm 
19. 295,25 
REVISED: OCT 1993  
						

							CHASSIS AND BODY 
DOORS DEFENDER 110 
6 
Right-hand rear side  door lock mechanism 
Right-Hand  front door 
lock mechanism 
REVISED: OCT 1993  
						

							CHASSIS AND BODY 
REMOVING THE DOOR  TRIM - DEFENDER 110 
Front and rear doors 
5. Lever off the window  regulator  center finisher 
and remove  the retaining  screw and withdraw 
the handle  and bezel. 
1. Prise off the two finishers  and remove  the two 
screws securing  the door  pull. 
2. Remove  the single  screw  behind  the remote 
control  lever. 
3.  Prise 
off the remote  control lever bezel. 
6. Using  a screwdriver,  carefully ease the trim 
away 
from the door. 
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  bezel. 
REVISED: OCT 1993 7  
						

							CHASSIS AND BODY 
9. Fit the  bezels to the locking  button and  Fitting regulator 
remote  control lever. 
10. Fit the  single  screw  behind  the remote  control 
lever.  channel. 
11. Fit the  door  pull and  secure  with two screws 
and  finishers. 
12. Fit the  window  regulator  handle and retain 
with  the single  screw  and finisher. 
5. Insert  the lifting  arm button into the lifting 
REMOVING WINDOW REGULATORS 
DEFENDER  110 - Rear side door 
Remove 
1. Remove the door  trim. 
2. Remove  the protective  weather sheet. 
3. Temporarily fit the handle  and wind  the 
window  up to its  fullest  extent  and support  the 
glass  in this  position,  with a length 
of timber, 6. Position  the regulator so that  the fixing  holes 
to prevent it falling  when removing  the  line-up with the holes  in the  mounting  panel. 
regulator. 
7. Secure  with the four  screws  and tighten 
regulator  to the  mounting  panel and withdraw 8. Temporarily  fit the  handle  and check  that 
the  regulator  whilst sliding  the lifting 
arm glass can be raised  and lowered  smoothly 
button 
from the  lifting  channel. To assist  this  without tight spots. 
operation,  remove the timber  and lower  the 
9. Fit the  weather  protection  sheet with adhesive 
glass. 
10. Fit  the  door  trim, regulator  handle, door pull, 
and bezels. 
4. Remove  the four  screws  retaining  the  evenly. 
8 REVISED: OCT 1993  
						

							CHASSIS AND BODY 
REMOVING EXTERIOR HANDLE 
DEFENDER  110 
- rear side  door 
Remove  Remove  REMOVING DOOR LOCKING  BUTTON 
DEFENDER  110 - Rear side door 
1. Remove  the door  trim, regulator  handle, door 1. Remove  the door  trim,  regulator  handle, door 
pull  and  bezels. 
pull and  bezels. 
2. Peel  back  sufficient of the weather  protection 2. Peel back  sufficient of the weather  protection 
sheet 
to gain  access  to the  handle  sheet to reveal  the mechanism 
mechanism. 
3. Release  the spring  clip securing  the button to 
3. Disconnect  the actuating  rod from  the handle  the operating  rod and  withdraw the rod from 
operating  lever.  the button. 
4. Remove  the two screws and withdraw  the 4. Remove the two screws securing the button to 
handle  and bezels. 
the door  panel  and remove 
the button 
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. 
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.  Re
-seal  the weather  protection  sheet and fit 
the door  trim, door  pull, regulator  handle and 
bezels. 
6.  Connect  the actuating  rod to the  handle 
operating  lever and secure  with spring  clip. 
7  Re-seal  the weather  protection  sheet. 
8.  Fit the  door  trim.  regulator  handle, door pull 
and  bezels. 
REVISED: OCT 1993 9  
						

							CHASSIS AND BODY 
Fitting control  lever 
REMOVING  REMOTE CONTROL LEVER 
DEFENDER  110 
- Rear side door 9. Fit the  plastic  retaining  clips to the rod 
Remove  assembly into position  and secure with the 
two screws. 
1. Remove  the door  trim,  door  pull, regulator  10, Connect  the control  rods to the  latch 
handle  and bezels.  assembly 
and secure  with the clips 
2.  Peel
-back  sufficient of the weather  protection 11. Fit the  plastic  retaining  rod clips to the 
sheet 
to gain  access  to the  remote  lever.  mounting 
panel. 
3. Remove the spring  clip and  disconnect  the 12. 
Connect  the control  rod to the locking  button 
control rod from  the locking  button.  and 
secure with the clip. 
13.  Re
-seal  the weather  protection  sheet and fit 
the trim  panel,  regulator  handle, door pull and 
bezels. 
REMOVING  DOOR LATCH  ASSEMBLY 
DEFENDER  110 
- Rear side door 
Remove 
1. Remove the door  pull. regulator  handle, 
bezels  and door 
trim. 
2. Peel-back  sufficient of the weather  protection 
sheet  to reveal  the latch. 
3.  Release  the remote  control lever rod from  the 
latch  assembly. 
4. Disconnect  the door  outer  handle  control rod 
from the latch  assembly. 
5.  Disconnect  the door  locking  button remote 
control  rod from  the latch  mechanism. 
6. Remove the three  retaining  screws and 
withdraw  the latch  assembly 
from the door 
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. 
10 REVISED:  OCT 1993  
						

							CHASSIS AND BODY 
Fitting the latch 7. Remove  the four  screws  retaining the 
mounting  panel to the  door  and remove the 
panel  complete  with rods  and control lever 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. 
REMOVING  DOOR GLASS DEFENDER 110 
Rear side door 
Remove 
1. Disconnect the door  check  rod from  the door 
post. 
2. Remove  the regulator  handle, door pull, 
bezels  and door  trim. 
3. Remove  the weather  protection  sheet. 
4. Remove the window  regulator  assembly. 
5. Disconnect  and remove  the door  locking 
button. 
6. Disconnect  the control  rods from the latch  and 
door  outer  handle  mechanism. 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. 
REVISED: OCT 1993  
						

							CHASSIS AND BODY 
11. Remove  the four  self-tapping  screws - two Fitting glass 
12. Remove  the inner  and outer  weather  strips 
each 
side 
- securing  the glass  lower channel. 
from  the door  sill 
15. Fit the  lift channel to the  new  glass  if not 
supplied  already fitted. 
16. Insert  the glass  into the lower  channels and 
carefully  push the glass  up to the top of the 
frame. 
17.  Secure  the lower  channels  with the four  self
- 
tapping  screws.  Ensure that the screw  heads 
are  screwed  down firmly  below  the bottom 
of 
the channels to prevent  damage to the glass. 
18. Fit the  door  check  rod and  bend  the end  stop 
back 
to the  closed  position. 
19. Fit check  stop torsion  bar and  secure  with the 
two nuts  and bolts. 
20.  Fit the  water  channel  and secure 
with the 
single  self
-tapping  screw. 
21.  Fit the  mounting  panel complete  with rods  and 
remote  control lever. 
22. Connect  the control  rods to the latch  and door 
outer  handle  mechanism. 
13.  Lower  the glass 
down  to  the  bottom of the 23. Fit the  door  locking  button and connect  the 
control  rad. 
door, lift the 
glass  over the lower  edge and 
24. Fit the  window  regulator. 
withdraw 
from the door 
14. Remove  the lift channel  from  the glass, if 25.  Fit the  door  inner  and outer  sill weather  strips 
necessary. 
26. Fit  and  re-seal  the weather  protection  sheet. 
27.  Fit the  door  trim, regulator  handle, door pull 
and 
bezels. 
28.  Connect  the door  check rod to the door  post. 
12 REVISED: OCT  1993  
						

							CHASSIS AND BODY 
REMOVING MOUNTING  PANEL DEFENDER 110 5 Slide  the window  regulator  arm from the 
Front doors mounting panel channel  and remove  the panel 
with  the remote  control lever and rod 
Remove 
1. Remove  the door  trim, window  regulator,  door 
pull,  bezels  and weather  protection  sheet. 
6. Engage the window  regulator  arm in the 
2.  Remove  the four  screws  securing  the window 
regulator  to the  mounting  panel. 
7 Connect the remote  control rod to the latch 
3. Remove  the five  screws  securing  the  mechanism and secure  with the clip 
mounting  panel 
to the door  frame. 
8. .Fit  the  mounting  panel and retain  with the five 
4.  Release  the remote  control lever 
rod from the  screws. 
latch  mechanism  and from  the plastic  clip in 
9. Secure  the window  regulator 
to the mounting 
the  mounting  panel.  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. 
Fitting  mounting  panel 
mounting panel channel. 
REMOVING  DOOR LOCKING BUTTON 
DEFENDER 110 - Front doors 
Remove 
1. Remove  the door  trim  regulator  handle, door 
pull  and  bezels. 
2. 
Peel back  sufficient of the weather  protection 
sheet 
to expose  the mechanism. 
3. Release  the spring  clip and  disconnect  the 
operating 
rod from  the latch  mechanism. 
4.  Remove  the 
two screws and withdraw  the 
locking  button assembly. 
REVISED:  OCT 1993