Land Rover Defender Workshop 1993 Rover Manual

							SECTION Body .................................................................. 
SECTION Electrical ........................................................... 
Published by Rover  Technical  Communication 
Publication  Part 
No. LRL0076USA ©1996 Rover Group Limited  
						

							BODY AND ELECTRICAL  CONTENTS 
Section 
Number 
Page 
- Rear  seat cushion ........................................................................\
................................. 1 
- Rear seat squab ........................................................................\
.................................... 1 
- Rear  seat belts ........................................................................\
...................................... 2 
- Side  trim panel ........................................................................\
...................................... 3 
- Interior roll-over bar ........................................................................\
............................... 4 
- Cubby box ........................................................................\
............................................. 6 
- Rear  grab handle ........................................................................\
.................................. 6 
........................................................................\
..........  7 
- Rear speaker panel ........................................................................\
................................ 7 
........................................................................\
................. 8 
- Rear  door trim casing ........................................................................\
............................ 9 
- Sun roof 10 
-  Front  headlining ........................................................................\
.................................. 11 
- Interior rear view  mirror ........................................................................\
........ 
- Sun visors ........................................................................\
........................................... 12 
- Front  seat belts ........................................................................\
................................... 13 
- Rear end  trim panel ........................................................................\
............................... 5 
........................................................................\
............................................... 
-  Exterior roll-over bar ........................................................................\
........................... 14 
- Rear  tow  bar ........................................................................\
...................................15 
- Rear wiper  motor ........................................................................\
................................... 1 
- Switch panel - rear door  services ........................................................................\
.......... 2 
- Switches - tailgate functions ........................................................................\
................. 3 
3 - Interior  lamp ........................................................................\
.......................................... 
- High level stop lamp ........................................................................\
............................... 4 
- Radio  speaker - rear ........................................................................\
............................. 5 
........................................................................\
...................... - High level stop lamp  bulb 4 
- Rear end lining 
- Rear headlining 
12  
						

							BODY 
REAR SEAT CUSHION REAR SEAT SQUAB 
Service  repair no - 76.71.26 
Service  repair no - 76.71.24 
Remove  Remove 
1. Release seat cushion stowage  strap. 
2. Remove four bolts  and spring  washers  and lift seat cushion. 
seat  cushion from  pivot brackets. 
3.  Remove  four bolts,  plain washers,  spring 
to body side. 
washers  and nuts.  Detach both pivot  brackets 
from  wheel arch. 
1. Release seat cushion stowage strap and  lower 
2. Slacken two bolts securing  seat squab brackets 
3.  Remove 
two bolts,  plain washers,  spring 
washers  and nuts  securing seat squab  to  wheel 
arch. 
4. Lift  seat squab and release brackets  from 
retaining  bolts. 
Refit 
4. Secure pivot brackets to wheel arch and tighten 
bolts 
to 10 Nm (7  Ibf.ft). 
5. Position  seat cushion  in pivot brackets  and 
secure with four  bolts and spring washers. 
6. Fit stowage  strap. 
Refit 
5. Lower seat squab brackets over  retaining bolts, 
6.  Secure  seat squab 
to wheel arch, tighten bolts to 
tighten bolts to 10 Nm (7 Ibf.ft). 
10  Nm 
(7 Ibf.ft). 
7.  Raise seat cushion and 
fit stowage strap. 
1  
						

							BODY 
REAR SEAT BELTS Refit 
Service  repair no - 76.73.18 
Remove 
6. Reverse  removal procedure, ensuring  seat belt 
fixing bolts are  tightened to 32 
Nm (24 Ibf.ft). 
1. Release  belt straps from buckles on  both seats. 
2. Raise  both seat cushions  and secure  with 
stowage straps. 
3. Unscrew bolt  and remove bracket  and inner seat 
belt straps. 
4. Unscrew  bolt and remove rear seat buckle strap 
from wheel  arch. 
5. Unscrew bolt and remove front seat  buckle strap 
from  interior roll
-over bar  mounting. 
2  
						

							BODY 
SIDE TRIM PANEL Refit 
Service  repair no 
- 76.13.70 
Remove 
10.  Fit new  spring  clips to the  three  brackets  on top 
11.  Carefully  pull trim  panel  behind interior roll
-over 
12.  Align  trim panel, ensuring  it is  correctly 
13.  Locate trim  panel spring  clips on  inner cant  rail 
edge of 
side trim panel. 
bar.  positioned  around side window. 
and  press firmly  down to secure top edge  of trim 
panel. 
support bracket  with body  side fixing  holes and 
secure  with four bolts  and washers. 
Do not fully 
tighten  at this  stage. 
15.  Fit trim stud  to secure bottom  edge 
of trim panel 
to  B/C  post. 
16.  Secure seat  belt guide  to ‘B/C  post,  tighten bolt 
to  32  Nm  (24 Ibf.ft) and  fit cap. 
18.  Fit rear seat  squab. See this Section 
. 
1. Remove rear seat  squabs. See this  Section. 
2.  Remove rear end  trim panel.  See this Section. 
3.  Prise cap from front seat  belt upper guide 
retaining  bolt. 
4.  Unscrew  retaining bolt and remove seat belt 
from  B/C’  post. 
5. Carefully prise trim  stud from B/C post. 
6. Remove four  bolts securing side trim  panel and 
forward  seat support bracket  to body  side. 
Collect  support bracket. 
7.  Release  top edge  of side  trim  panel  by striking 
8.  Carefully  pull trim  panel  rearwards  to clear 
9. Remove  side trim panel  from vehicle.  14. 
Align bosses  of trim  panel  and forward  seat 
upwards  with the hand  to disengage  three spring 
17. Fit rear  end trim panel.  See this Section 
clips. 
interior  roll
- over bar. 
3  
						

							BODY 
6. Remove 2 tom bolts and nuts from  both sides 
and  detach  centre section  of roll
-over  bar 
assembly 
. 
7. Remove  torx bolt, from  both sides,  securing 
roll
-over  bar to body  side mounting brackets. 
8. Remove  3 bolts  and washers,  from both sides, 
securing  lower roll
-over bar brackets  to front  of 
wheelarch. 
9. Remove 2 tom bolts  and washers, from  both 
sides, securing  roll
-over bar upper  mountings  to 
roof  fixing  brackets  and carefully  lower complete 
assembly to  the floor. 
remove  front seat belt inertia  reels and rear seat 
belts from  roll
-over bar mounting. 
roll
-over  bar rearwards to  clear wheelarches. 
12. Remove  roll-over bar from vehicle. 
NOTE:  Assistance  may be required  to remove the 
roll
-over  bar. 
INTERIOR 
ROLL-OVER BAR 
Service  repair 
no - 76.11.40 
Remove 
1. Remove  rear seat squabs.  See this Section. 
2.  Remove  rear end trim  panels.  See this Section. 
3.  Remove  side trim  panels. See this Section. 
4.  Release  retaining  straps and remove  tool bag 
5. Remove 4 bolts securing centre section  of 
from 
roll
-over bar. 
roll
-over  bar and seat  belt stalks  to floor.  On the 
of audible warning  circuit at belt  stalk. 
10. Unscrew  retaining bolts,  from  both sides, and 
drivers side, disconnect  harness plug Connector 
11. Supporting from  both sides, raise  and tilt 
4  
						

							BODY 
Refit REAR END TRIM PANEL 
13. Supporting  from  both sides, position  roll-over bar 
on  the floor  in front  of wheelarches. 
14.  Secure front  seat belt inertia reels  and rear seat 
belts to roll
-over  bar mountings.  Tighten bolts to 
32Nm 
(24 Ibf.ft). 
15.  Raise  roll
-over bar assembly  and secure  to roof 
mounting brackets. Tighten bolts to  45  Nm 
(33 
Ibf.ft). 
16.  Secure  roll
-over bar to wheelarches.  Tighten 
bolts to  45 Nm  (33 Ibf.ft). 
17.  Secure  roll
-over bar to  body  side mounting 
brackets, tightening bolts to 
45 Nm  (33 Ibf.ft). 
18.  Secure  centre section  to main  roll
-over bar,  but 
do  not  fully tighten fixing bolts  at this  stage. 
19.  Reconnect  drivers seat belt audible  warning 
Service repair no - 76.13.71 
Remove 
1.  Pull  edge  of rear end trim  panel firmly  to release 
the  two spring  retaining clips  from vertical rail  at 
door  aperture. 
2.  Remove  rear end trim  panel. 
3.  Fit new  spring clips to  the two brackets  on side 
Refit 
of trim  panel. 
mounting brackets to chassis. Tighten bolts  to 32 
21.  Fully tighten roll
-over  bar centre section retaining 
24.  Fit  rear  and  end  trim  panels. See this Section. 
4. Position outboard edge  of trim  panel  in corner  to 
abut  side trim  panel and locate  spring clips on 
vertical rail. 
position. 
5. Press  edge of trim  panel firmly  to secure  in 
5 
harness plug. 
20.  Secure seat belt stalks and roll-over bar floor. 
Nm  (24  lbf.ft). 
bolts to 45 Nm (33 lbf.ft). 
22. Position tool bag and secure to roll-over bar. 
23.  Fit side trim panels. See this Section. 
25.  Fit rear seat squabs.  See this Section.  
						

							BODY 
CUBBY BOX REAR GRAB  HANDLE 
Service  repair 
no - 76.25.04 
Remove  Remove  Service repair 
no - 76.58.35 
1. 
Remove  radio/cassette player. 
2. Open cubby  box lid and remove  two caps 
3.  Remove  fixing bolts  and washers. 
4.  Remove 
2 screws  and lift cup holder from cubby 
box. 
5. Unscrew  two bolts securing  front of cubby  box to 
floor  mounting. 
6. Lift cubby  box and  unthread  radio/cassette 
player leads through cubby  box base. 
7. Remove cubby  box.  1. 
Carefully  prise top and  bottom  edges of finisher 
caps from grab handle  and then hinge outwards 
to gain access  to fixing  screws. 
2. Remove 4 fixing screws and detach grab handle 
from  rear.  end 
trim panel. 
concealing 
fixing bolts. 
Refit 
3. Position  grab handle on rear end trim  panel and 
secure with 
4 fixing  screws. 
4. Press  finisher caps over  screws. 
Refit 
8. Position cubby box to mounting  and insert  radio/ 
9.  Secure front  of cubby box  to floor and fit cup 
10. Open cubby  box lid, secure  in position  and fit 
11 . Fit radio/cassette  player. 
cassette 
player leads. 
holder. 
bolt caps 
6  
						

							BODY 
REAR END LINING REAR 
SPEAKER  PANEL 
Service  repair 
no - 76.64.12 
Remove  Remove  Service 
repair no - 76.13.13 
1. Remove rear  end trim panel. See this Section. 
2.  Remove  rear grab  handles.  See this Section. 
3.  Carefully  prise out 6 trim studs securing  rear end 
4.  Remove rear end  lining. 1. Raise seat cushion and fit  stowage strap. 
2. Remove  rear end trim  panel.  See this Section. 
3.  Remove  rear speaker.  See Electrical. 
4. Peel back carpet  and remove  two screws 
securing speaker panel 
to wheelarch. 
5. Prise top edge  of panel  down to  release from 
body  channel. 
6. Remove  speaker panel. 
lining 
to mounting brackets. 
Refit 
5. Position  rear end  lining on mounting brackets 
6. Fit  rear grab  handles  See this Section. 
7.  Fit  rear end trim  panel See this  Section. 
and secure 
with 
6 trim studs. 
Refit 
7. Position  speaker  panel on wheel  arch. 
8. Press top  edge of panel  down firmly  and locate 
9.  Secure speaker  panel to wheel arch with 
2 
under body  channel. 
screws  and reposition  carpet. 
10. Fit  rear speaker.  See Electrical. 
11. Fit rear end trim  panel. See this Section . 
7  
						

							BODY 
5. Remove rear interior  lamp. See Electrical 
7. Carefully prise  out 5 trim  studs securing rear and 
front  headlining  to roof  mounting brackets. 
8. Release  front comers  of headlining  from cant 
rail,  on both  sides. 
9. Pull headlining forwards  sufficiently to clear rear 
end  lining  mounting  brackets. 
10. Release rear corners  of headlining  from cant rail, 
on both  sides. 
11 . Lower rear headlining  from roof and  remove from 
vehicle. 
NOTE:  Take care not to bend  headlining  on 
removal  and refitting. 
REAR 
HEADLINING 
6. Remove  interior roll-over bar. See  this  Section 
Service  repair no - 76.64.11 
Remove 
1. Remove  rear end trim  panel.  See this  Section. 
2.  Remove  side trim  panels.  See this  Section. 
3.  Remove  rear grab handles.  See this  Section. 
4.  Remove rear  end lining.  See this  Section 
8