Land Rover Defender Workshop 1993 Rover Manual

							CHASSIS AND BODY 
Fitting  locking button  Fitting regulator 
5. Secure  the locking  button assembly to the 6. Insert the regulator  operating  arms into the 
door with the two screws.  channels. 
6 Connect 
the operating  rod to the  latch 7 Fit and  tighten  the mounting  panel lower 
mechanism  and secure  with the spring  clip 
screws and tighten  the upper  screws. 
7. Re-seal the weather  protection  sheet and fit 8. Position  the holes  in the  regulator to line-up 
the door  trim, door  pull. regulator  handle, and  with the holes  in the  mounting  panel and 
bezels.  secure 
with the four  screws. 
9. Temporally fit the regulator  handle and check 
that  the glass  can be raised  and lowered 
without  tight spots. 
10. Secure  the weather  protection  sheet with 
11.  Fit the  door  trim, regulator  handle, door pull 
REMOVING  WINDOW REGULATOR 
DEFENDER  110 - Front  doors 
Remove 
adhesive. 
1. Remove  the door  trim.  and bezels. 
2. Remove  the weather  protection  sheet. 
3.  Temporarily 
fit the  handle  and position  the 
window  half open  and support  with a length  of 
timber. 
mounting  panel 
to the door  and slacken  the 
three  upper  screws. 
1. Remove  the door  pull, regulator  handle, 
5. Remove the four  screws  retaining  the window  bezels and door  trim. 
regulator  to the  mounting  panel and slide  the 
2. Peel back  sufficient  of the  weather  protection 
operating  arms from the channels  attached to  sheet to gain  access  to the  remote  lever. 
the  glass  and mounting  panel and remove 
the 3. Release  the spring  clip and  disconnect  the 
regulator.  control 
rod from the latch  mechanism. 
4. Release the control rod from the  plastic  clip in 
the  mounting  panel. 
REMOVING REMOTE  CONTROL LEVER 
DEFENDER  110 - Front  doors 
4. Remove  the two lower screws  securing  the Remove 
14 REVISED: OCT 1993  
						

							CHASSIS AND BODY 
5. Remove 
the two screws securing  the remote 3. Disconnect  the operating rod from the handle 
control  lever to the  mounting  panel and  mechanism. 
withdraw  the lever  and control  rod. 
4 Disconnect  the rod from the locking  barrel 
lever. 
Fitting remote control  lever 5. Remove  the two screws and withdraw  the 
handle  assembly. 
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 
mounting  panel. 
10.  Secure  the weather  protection  sheet with 
adhesive. 
11. Fit  the  door trim, regulator  handle, door pull 
and  bezels. 
REMOVING  EXTERIOR DOOR HANDLE 
DEFENDER 
110 - Front doors 
Remove Fitting the  handle 
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. 
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. 
9. Carry-out  instructions for fitting  the mounting 
panel  and door 
trim and  fittings. 
REVISED: OCT 1993 15  
						

							CHASSIS AND BODY 
REMOVING THE DOOR LATCH ASSEMBLY 
DEFENDER 110 - Front  doors 
Remove 
7.  Remove  the three  screws  securing  the latch 
8. Whilst  taking care not to damage  the runner, 
ease 
it away  from the latch  and manoeuvre 
the latch  assembly  from the door 
assembly  to the  door. 
1 Carry  out the instructions  to remove  the 
mounting  panel and support  the glass  with 
timber. 
2.  Disconnect  the control  rod from  the handle 
operating  lever. 
3.  Disconnect  the control 
rod from  the locking 
lever 
on the  handle. 
4. Disconnect  the locking  button control  rod from 
the  latch  mechanism. 
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. 
6. Remove  the two self-tapping Screws retaining 
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. 
5. Remove  the two screws and remove the 
handle assembly from  the door. See Exterior 
door handle. 
the 
lower end of the window  glass runner. 
16 REVISED: OCT 1993  
						

							CHASSIS AND BODY 
REMOVING  GLASS DEFENDER 110 
- Front doors 
Remove 
1 Carry-out the  instructions to remove  the 
mounting  panel. 
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. 
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. 
Fitting glass 
5 
Taking  care not to damage  the paint  work. 
prise  the exterior  waist weather  strip from  the 
door  as illustrated. 
6. Remove  the timber  support  and lower  the 
glass  to the  bottom 
of the door. 
8. lnsert  the glass  into the runners at an angle 
9. Whilst  lifting me 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. 
17 REVISED: OCT 1993  
						

							CHASSIS AND BODY 
6. Withdraw the lock barrel from the exterior 
door  handle  complete  with the locking  sleeve 
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 
panel. 
14. Fit  the  door  trim,  window  regulator,  door pull 
and  bezels. 
REMOVING  LOCKING BARREL DEFENDER 110 
- Front doors 
Remove 
7.  To remove the barrel  from the plastic  retaining 
sleeve,  depress the spring  loaded  button and 
1. Remove  me regulator  handle, door pull,  withdraw the sleeve. 
bezels,  door trim and weather  protection  sheet. 
2. Carry-out  the instructions to remove  the 
mounting  panel. 
3. Raise and support the glass  to gain  access  to 
me  latch  mechanism 
4 Release  the spring  clip and  disconnect  the rod 
from 
the lock operating  lever. 
5. Remove the single screw and withdraw  the 
lock lever assembly. 
18 REVISED: OCT 1993  
						

							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 Remove 
number on the accompanying  key. 
REMOVING REAR SIDE WINDOW  TRIM 
DEFENDER 
110 
1. To gain  access  to the  trim  lower  fixings 
8. Push the plastic  retaining  sleeve over the  remove the rear  seat  and squab frame 
complete. 
2. Remove  the plastic  cover and the seat belt 
anchorage  bolt from  the 
C post. 
barrel 
until the spring  loaded  peg locks 
it into 
position. 
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. 
9 
3. Remove  the lower  anchorage  bolt for the 
same  seat belt. 
4. Remove  the seat  belt aperture  finisher from 
the trim  panel  and remove  the rear  quarter 
light  trim 
from the side  concerned. 
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. 
19 REVISED:  OCT 1993  
						

							CHASSIS AND BODY 
8. The top edge of the trim  is held to the inner 
5.  Using  a screwdriver,  carefully lever the trim 
retaining  button from the 
C post.  The button  cant rail by three  spring clips. Strike upwards 
is held  by a fir-tree  type peg.  with the hand,  as illustrated, to release the 
trim. 
6. Remove  the trim  lower  three  fixings.  The 9. Feed the seat  belt through  the aperture  and 
7.  The  rear  and center  fixings 
are a screw, To refit 
remove  the trim  from  the vehicle. 
washer  and 
a nut welded  to  a  plate.  When  the 
boxed section of the attachment  side member. 
10. Feed  the seat  belt through  the trim  aperture 
fasten  the 
top edge of the trim to the inner 
cant  rail with  the three  spring  clips. 
20 REVISED: OCT 1993 
forward  fixing  is  a  screw,  two  washers  and  a 
nut. 
screw  is  removed,  the  plate  will  fall  into  the  
						

							CHASSIS AND BODY 
11. Secure  the lower  edge of the trim  with  the 
three  screws  by reversing  the removal 
process.  Secure the rear  and centre  screws 
first  and  note  that the nut is to  the  rear,  the 
plate  towards  the trim. 
12. Fit the  plastic  retaining  button.  upper anchorage. 
13.  Fit the  seat  belt lower  anchorage  and secure 
with  the special  bolt, spacer  and washers,  as 3. Carefully  lever
-out the plastic  button and 
illustrated.  tighten the bolt  to 20,3  Nm. 
14.  Similarly,  fit the  seat  belt upper  anchorage 
and  tighten  the special  bolt 
to 20,3 Nm. Fit the Refit 
finisher  to the  seat  belt aperture  in the  trim 
panel  and the plastic  cover to the  anchorage 
4. Reverse  the removal  procedure  ensuring that 
bolt.  the upper  anchorage  bolt and fittings  are 
correctly  fitted and tightened 
to the specified 
torque  as described  in instruction  14 for 
refitting  the rear  side trim. 
5.  Fit the  plastic  cover over the anchorage  bolt 
and  secure  the lower  end 
of the trim  with  the 
retaining  button. 
REMOVING B POST TRIM DEFENDER  110 
Remove 
1. Remove the plastic  cover from the seat  belt 
2.  Remove  the upper  anchorage  bolt and fittings 
remove  the trim. 
15.  Fit the  seat  and squab  frame and secure  the 
seat  cushion  to the 
frame with the tapes. 
16. Fit  the  rear  quarter  light trim. 
21 REVISED: OCT 1993  
						

							CHASSIS AND BODY 
REMOVING REAR QUARTER LIGHT TRIM 
DEFENDER 110 
Remove 
1. Pull the trim  panel  away from the quarter  light 
with  fingers  thereby  releasing  the retaining 
spring  clips from  the vertical  rail and  withdraw 
the  panel. 
REMOVING  GRAB HANDLES  DEFENDER  110 
Remove 
1. Lift the  plastic  finishers to expose  the securing 
screws. 
2. Remove  the four  screws to release  the grab 
handle. 
NOTE: In  order  to remove  the trim above the 
door  between  the B and 
C post on 110 
Station  Wagons,  the B post  trim as well as the 
grab handle  must be removed.  The trim  above 
2. Reverse  the removal  procedure  whilst the door is held by clips, the same as used  for the  side trim 
Refit 
3. Reverse  instructions 1 and 2. 
Refit 
ensuring  that the two  metal  lugs locate  behind 
the  side  trim. 
3.  Align  the 
two spring  clips with the vertical rail 
and tap the panel into position  with the hand. 
22 REVISED: OCT 1993  
						

							CHASSIS AND BODY 
DOOR LOCK, REAR DOOR  DEFENDER 110 
FRONT  AND REAR DOORS  DEFENDER 90 
Removal,  Defender 110 
Refitting 
15. Apply sealant  to the  lock  retainer  plates 
16.  Fit the  lock  to the  door  with a new  gasket  and 
complete  with the lock  trim 
1. Remove  the grab  handle  from the rear  door 17 Secure  with the retainer  plates screws. 
2 Remove  the rear  wiper  motor  cover.  washers and nuts. 
3. Remove  the harness  cover from the rear  door  Close the door  and check  for correct  latching 
4  Remove  the rear  door  trim pad.  with the striker.  Adjust the striker  as 
5.  Remove  the screws,  washers  and nut retainer  necessary. 
securing  the top  of the  lock  to the  door.  19. Refit  the trim  pad,  the harness  and wiper 
6.  Remove  the nuts,  washers  and screw  retainer 
securing  the 
bottom of the lock  to the  door. 
7.  Withdraw  the lock  complete  with trim. 
Removal,  Defender 90 
8. Remove  the trim  from  lock. 
9. Remove  the door lock gasket. 1. Remove  the screws,  washers  and nut retainer 
10.  Clean  sealant 
from the retainer  plates. (10) securing  the  top of the lock to the  door 
2.  Remove  the nuts,  washers  and screw  retainer 
(10)  securing  the bottom  of the 
lock to the 
door. 
18 
motor  covers  and the grab  handle. 
Barrel  removal 
11. Insert  the key  in the  barrel. 3. Withdraw  the lock. 
12.  Depress  the lock  barrel  plunger. 
13.  Withdraw  the barrel 
from the  lock. Refitting 
Barrel  refitting. 
4. Apply  sealant  to the  lock  retainer  plates. 
5.  Fit the  lock  to the  door  with a new  gasket. 
14.  Refit the barrel 
in reverse of removal.  6. Secure  with the retainer  plates, screws, 
washers  and nuts. 
7. Close  the door  and check  for correct  latching 
with  the striker. 
8.  Adjust  the striker  as necessary 
ADDITION:  OCT 1993 23