service LAND ROVER DEFENDER 1996 Workshop Manual

76CHASSIS AND BODY
26
REPAIR FRONT HEADLINING - 90 STATION WAGON
Service repair no - 76.64.10
Remove
1.Remove sun roof headlining finisher.
2.Remove sun visors
See Sun visors.
3.Remove interior lamp
See ELECTRICAL,
Repair, Interior lamp
.
4.Remove interior mirror and mounting plate
See
Interior mirror
.
5.Remove 4 retaining screws and detach both 'A'
post trims.
6.Remove caps and unscrew front seat belt fixing
bolts from 'B' posts.7.Carefully prise side trim panel cap fastener from
'B' posts.
8.Carefully prise 2 cap fasteners, from both sides,
securing headlining to body at door aperture.
9.Carefully prise out 5 cap fasteners securing front
and rear headlinings to roof.
10.From both sides, pull side trim panel inwards
enough to release rear corners of front
headlining.
11.Lower headlining and remove from vehicle.NOTE: Take care not to bend the
headlining on removal and refitting.
Refit
12.With assistance, raise headlining to roof.
13.Carefully pull side trim panel inwards, on both
sides, and slide headlining behind trim panel.
14.Position front headlining into recess of rear
headlining and secure both to roof mounting
brackets with 5 cap fasteners.
15.Secure both sides of front headlining to body at
door apertures with cap fasteners.16.Fit side cap fasteners at 'B' posts.
17.Secure seat belts to 'B' posts and tighten bolts to
32 Nm (24 lbf/ft).Fit caps to bolts.
18.Fit 'A' post trims.
19.Fit interior mirror
See Interior mirror.
20.Fit interior lamp
See ELECTRICAL, Repair,
Interior lamp
.
21.Fit sun visors
See Sun visors.
22.Fit sun roof headlining finisher.

CHASSIS AND BODY
27
REPAIR REAR HEADLINING - 90 STATION WAGON
Service repair no - 76.64.11
Remove
1.Remove side trim panels
See Side trim panel.
2.Remove rear end lining
See Rear end lining.
3.Remove rear interior lamp
See ELECTRICAL,
Repair, Interior lamp
.
4.Carefully prise out 5 trim studs securing rear and
front headlining to roof mounting brackets.5.Release front corners of headlining from cant
rail, on both sides.
6.Pull headlining forwards sufficiently to clear rear
end lining mounting brackets.
7.Release rear corners of headlining from cant rail,
on both sides.
8.Lower rear headlining from roof and remove
from vehicle.NOTE: Take care not to bend headlining
on removal and refitting.
Refit
9.With assistance, position rear headlining to roof
and locate rear corners in cant rail.
10.Push headlining rearwards and position over
rear end lining mounting brackets.
11.Locate front corners of headlining in cant rail.12.Position front edge of rear headlining over front
headlining and secure with trim studs.
13.Adjust rear headlining to achieve good fit at all
corners.
14.Fit rear interior lamp
See ELECTRICAL,
Repair, Interior lamp
.
15.Fit rear end lining
See Rear end lining.
16.Fit side trim panels
See Side trim panel.

76CHASSIS AND BODY
28
REPAIR TAIL DOOR TRIM CASING
Service repair no - 76.34.09
Remove
1.Unscrew 2 bolts and remove grab handle from
rear door.
2.Remove 2 screws and detach wiper motor cover.
3.Remove 7 screws securing trim casing to door.
4.Remove 2 screws and lift wiper motor harness
cover from harness support bracket.
5.Carefully release 8 clips securing trim casing to
door.
6.Remove trim casing and collect door lock cover.
Refit
7.Position door lock cover, fit trim casing and
secure with clips.
8.Fit harness cover and secure with two screws.
9.Secure door panel with retaining screws.
10.Position wiper motor cover and secure with 2
screws.
11.Position grab handle and secure with 2 bolts.TAIL DOOR LOCK
Service repair no - 76.37.16
Remove
1.Remove door casing
See Tail door trim
casing
.
2.Remove screws, washers and nut retainer plate
securing top of lock to door.
3.Remove nuts, washers and stud retainer plate
securing bottom of lock to door.
4.Withdraw lock assembly.
5.Remove door lock gasket.
6.Clean sealant from retainer plates.
7.Insert key into barrel.
8.Depress lock barrel plunger and withdraw barrel
from lock.
Refit
9.Fit new barrel into lock.
10.Apply sealant to lock retainer plates.
11.Fit lock to door with a new gasket.
12.Secure with retainer plates, screws, washers
and nuts.
13.Close door and check for correct latching with
striker. Adjust striker as necessary
See Tail
door striker - adjust
.
14.Fit door casing
See Tail door trim casing.

CHASSIS AND BODY
29
REPAIR TAIL DOOR STRIKER - ADJUST
Service repair no - 76.37.25
Adjust
1.Loosen striker securing screws.
2.Adjust striker and retighten screws.
3.Close door and check for correct latching with
door lock.
4.Carry out further adjustment as necessary. If full
adjustment cannot be achieved carry out
following:
5.Remove striker and nut plate.
6.Elongate holes in body metal which is
sandwiched between striker and nut plate.
7.Refit striker and adjust as necessary.

76CHASSIS AND BODY
30
REPAIR SUN ROOF
Service repair no - 76.83.01
Remove
1.Open sun roof fully.
2.Disengage spring lock from operating handle
catch.
3.Holding sun roof at both sides, release hinges
from locating brackets at front of outer frame.4.Remove sun roof.
5.Starting from centre rear, peel headlining finisher
from inner frame.
6.Remove 18 screws securing inner frame to outer
frame and detach inner frame.
7.Lift outer frame from roof.
NOTE: Assistance may be required to
remove the sun roof assembly.
Refit
8.Clean roof area around outer frame seating.
9.Position outer frame on roof.
10.Fit inner frame to headlining and secure to outer
frame with 18 screws but do not fully tighten.
11.Check alignment of inner and outer frames with
roof mounting and headlining, adjust as
necessary, and fully tighten fixing screws to
10
Nm (7 lbf/ft).
12.Starting from centre rear, fit headlining finisher
lip into locating channel of inner frame.
13.Press finisher firmly over inner frame and
continue around complete frame, ensuring
finisher lies flat on headlining.
14.Fit sun roof hinges fully into locating brackets on
outer frame, and lower the glass panel.
15.Engage operating handle catch with spring lock
of outer frame and close sunroof.

CHASSIS AND BODY
31
REPAIR INTERIOR MIRROR
Service repair no - 76.10.51
Remove
1.Prise interior mirror arm from mounting plate.
2.Remove 3 screws and remove mounting plate
from headlining.
Refit
3.Fit mounting plate to headlining.
4.Locate lower lug of mirror arm in mounting plate
aperture.
5.Press mirror arm firmly to engage spring clip in
mounting plate aperture.SUN VISORS
Service repair no - 76.10.47
Remove
1.Raise sun visor.
2.Remove 2 screws and collect sun visor.
Refit
3.Position sun visor and secure with 2 screws.

76CHASSIS AND BODY
32
REPAIR BONNET LOCK
Service repair no - 76.16.21
Remove
1.Open bonnet.
2.Mark position of guide plate and lock to bonnet
platform.
3.Remove 8 screws securing grille.
4.Remove grille.
5.Remove 2 bolts securing guide plate and lock.
6.Remove guide plate.
7.Release spring securing lock to bonnet platform.
8.Slacken clamping bolt securing bonnet release
cable.
9.Remove lock.
Refit
10.Fit spring between lock and bonnet platform.
11.Position lock and guide plate to bonnet platform
and nip up bolts.
12.Position guide plate and lock to position marks
and tighten bolts to
10 Nm (7 lbf/ft).
13.Fit cable to lock and tighten clamping bolt.
14.Check operation of release cable and adjust if
necessary.
15.Fit grille and tighten securing screws.
16.Close bonnet.BONNET RELEASE CABLE
Service repair no - 76.16.29
Remove
1.Open bonnet.
2.Remove 8 screws securing grille.
3.Remove grille.
4.Slacken clamping bolt securing bonnet release
cable.
5.Remove cable from lock.
6.Release cable from clip on underside of bonnet
platform.
7.Feed cable through valance and collect
grommet.
8.Release cable from clip fixed to wheelarch under
expansion tank.
9.Loosen clamping nut securing bonnet release
handle to mounting bracket.
10.Remove bonnet release handle from mounting
bracket.
11.Withdraw cable through bulkhead.
Refit
12.Feed cable through bulkhead and fit bonnet
release handle to mounting bracket. Tighten
clamping nut.
13.Route cable behind expansion tank and fit to
securing clip.
14.Feed cable through valance.
15.Fit grommet between cable and valance.
16.Fit cable to securing clip on underside of bonnet
platform.

76CHASSIS AND BODY
34
REPAIRREV: 05/99 LOWER FASCIA PANEL (HEATER DUCT)
ASSEMBLY
Service repair no - 76.46.05
Remove
1.Disconnect battery.
2.Remove steering wheel
See STEERING,
Repair, Steering wheel
.
3.Remove steering column nacelle
See
STEERING, Repair, Steering column nacelle
.
4.Remove instrument panel
See INSTRUMENTS,
Repair, instrument panel
.
5.Release heater cable at control lever
See
HEATING AND VENTILATION, Repair, Heater
control cable - air distribution
.
6.Remove 2 screws, withdraw switch panel from
lower fascia and disconnect switch multi-plugs.
7.Prise out Land Rover decal and remove screw
securing grab handle to crash pad.
8.Remove lower screw and lift grab handle from
lower fascia panel.
9.On RH drive vehicles only, remove screw
securing LH side of finisher to wiper motor cover.
10.Remove 4 screws and remove both demister
vents from crash pad.
11.Remove 3 screws securing crash pad to fascia
bulkhead.
12.Remove crash pad.
13.Remove radio, if fitted.
14.Remove 2 trim studs securing radio housing to
trim panel. Remove radio housing.

CHASSIS AND BODY
37
REPAIR REV: 05/9947.Connect leads and plugs to auxiliary switches
and clock.
48.Secure switch panel to lower fascia panel and
switch cover.
49.Position radio housing, if applicable, and feed
radio multi- plug, aerial and speaker leads from
switch cover to radio housing.
50.Secure radio housing to trim panel.
51.Fit radio connections and secure radio in
housing.
52.Fit crash pad to fascia bulkhead.
53.Fit demister vents in crash pad.
54.Fit grab handle to lower fascia panel and secure
to crash pad. Refit Land Rover decal.
55.Connect multi-plugs to rear screen, hazard and
interior lamp switches and fit switch panel to
fascia panel.
56.Fit heater control cable
See HEATING AND
VENTILATION, Repair, Heater control cable -
air distribution
.
57.Fit instrument panel
See INSTRUMENTS,
Repair, instrument panel
.
58.Fit steering column nacelle
See STEERING,
Repair, Steering column nacelle
.
59.Fit steering wheel
See STEERING, Repair,
Steering wheel
.
60.Reconnect battery.FRONT UNDERTRAY
Service repair no - 76.11.81 - Front undertray
Service repair no - 76.11.85 - Acoustic pad
Remove
1.Raise vehicle on ramp.
2.Position support under chassis front
crossmember.
3.Lower ramp to give clearance between axle and
undertray.
4.Remove 4 nuts, disconnect propeller shaft from
front axle, and move aside.
5.Remove 2 bolts securing undertray to chassis
front crossmember.
6.Remove nut securing undertray to bump stop
front fixing bolt on both sides.
7.Remove 2 bolts securing sides of undertray to
rear undertray.
8.Pull front undertray forwards to release flanges
from rear undertray.
9.Lower undertray to clear steering box etc. and
manouvre rearwards over axle.
10.Remove front undertray.
11.If necessary, remove 8 fasteners to release
acoustic pad from undertray.

76CHASSIS AND BODY
38
REPAIR Refit
12.If applicable, fit acoustic pad to undertray.
13.Fit undertray in position, ensuring flanges are
correctly located in rear undertray.
14.Secure undertray to chassis front crossmember,
bump stops and rear undertray. Tighten fixings
to
14 Nm (10 lbf/ft).
15.Fit propeller shaft to front axle and tighten nuts
to 47 Nm (35 lbf/ft).
16.Raise ramp to remove chassis support.
17.Lower ramp.REAR UNDERTRAY
Service repair no - 76.11.80 - Rear undertray
Service repair no - 76.11.82 - Acoustic pad
Remove
1.Raise vehicle on ramp.
2.Remove 2 bolts securing sides of undertray to
front undertray.
3.Remove 2 bolts securing rear undertray to
chassis crossmember brackets.
4.Remove bolt securing undertray to RH side of
chassis.
5.Pull undertray rearwards to release from flanges
of front undertray.
6.Remove rear undertray.
7.If necessary, remove 7 fasteners and release
acoustic pad from undertray.
Refit
8.If applicable, fit acoustic pad to undertray.
9.Fit undertray in position, ensuring flanges of front
undertray are correctly located.
10.Secure undertray to chassis crossmember, RH
chassis side, and front undertray. Tighten fixings
to
14 Nm (10 lbf/ft).
11.Lower ramp.