LAND ROVER DEFENDER 1996 Workshop Manual

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.

CHASSIS AND BODY
33
REPAIR 17.Fit cable to lock and tighten clamping bolt.
18.Check operation of release cable and bonnet
lock and adjust if necessary.
19.Fit grille and tighten screws.
20.Close bonnet.

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
35
REPAIR REV: 05/99
15.If fitted, remove 2 screws, washers and nuts
securing auxiliary switch panel to lower fascia
panel and switch cover.
16.Withdraw switch panel and disconnect switch
leads.
17.Remove 2 screws securing switch cover to
parcel tray.
18.Remove fuse box cover.
19. Models with hand throttle:
Remove fuse box LH retaining screw.
Pivot fuse box down to gain access to lower
inner hand throttle cover fixing screw.
Remove 4 screws and lift up hand throttle cover
from lower fascia panel.
20.Remove 2 screws and remove both footwell
vents from lower fascia panel.
21.Remove single screw and detach door check
strap cover from LH and RH doors.
22.Remove 3 screws securing wiper motor cover to
fascia bulkhead.
23.Release locating pins from fascia panel, lower
wiper motor cover and, if applicable, disconnect
radio speaker leads. Retain wiper motor rack
cover. On LH drive vehicles, disconnect
multi-plugs from rear of switch panel.
24.Prise out 2 large and 5 small cap fasteners
securing trim panel to parcel shelf and fascia
bulkhead.
25.Carefully fold back trim panel to clear fresh air
vent operating levers and remove panel from
parcel shelf.

76CHASSIS AND BODY
36
REPAIRREV: 05/99 26.Release demist hose and lift parcel shelf from
lower fascia panel (heater duct). Feed main
harness leads and plugs through aperture in
parcel shelf.
27.Remove parcel shelf.
28.Remove 7 screws securing bottom edge of lower
fascia panel to fascia bulkhead, noting position
of both footwell cover retaining plates.
29.Remove both retaining plates and lower footwell
covers.
30.Unscrew 2 retaining bolts securing top edge of
lower fascia panel to bulkhead.
31.With assistance, lower fascia panel and, if
applicable, disconnect RH radio speaker leads.
32.Remove fascia panel from vehicle.Refit
33.Position lower fascia panel to bulkhead,
reconnect RH speaker leads, if applicable, and
secure top edge with 2 bolts.
34.Locate RH footwell cover retaining plate under
bottom edge of fascia panel and secure with 3
screws.
35.Repeat operation for LH footwell cover retaining
plate.
36.Fit remaining lower fascia panel fixing screws.
37.Locate parcel shelf. Ensure all radio and
auxiliary switch panel harness leads and plugs
are fed through aperture in parcel shelf.
38.Fit demist hoses into heater duct of lower fascia
panel. Ensure flanges of hose grommets are
correctly seated.
39.Fit trim panel and secure with cap fasteners.
40.Reconnect LH speaker leads, if applicable,
locate wiper motor cover pins in lower fascia
panel and secure wth 3 screws. Ensure wiper
rack cover is correctly seated. On LH drive
vehicles, reconnect multi-plugs to rear of switch
panel.
41.Secure finisher to wiper motor cover.
42.Fit door check strap covers on both sides.
43.Fit footwell vents to lower fascia panel.
44. Models fitted with hand throttle:
Fit hand throttle cover.
Secure LH side of fuse box.
45.Fit fuse box cover.
46.Fit auxiliary switch cover to parcel tray, if
applicable.

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.

CHASSIS AND BODY
39
REPAIR ACCESS PANEL - FRONT UNDERTRAY
Service repair no - 76.11.85 - Access panel
Service repair no - 76.11.83 - Acoustic pad
The access panel is provided in the front undertray to
enable fitment of the wading plug into the engine
timing cover.
Remove
1.Raise vehicle on ramp.
2.Remove 5 bolts securing access panel to front
undertray.
3.Remove access panel.
4.If necessary, remove 5 fasteners and release
acoustic pad from access panel.
Refit
5.If applicable, fit acoustic pad to access panel.
6.Fit access panel to front undertray, Tighten
fixings to
14 Nm (10 lbf/ft).
7.Lower ramp.ACCESS PANEL - REAR UNDERTRAY
Service repair no - 76.11.84
The access panel is provided in the rear undertray to
enable fitment of the wading plug or timing tool
LRT-12-044in the flywheel housing, and access to
the engine oil sump drain plug.
Remove
1.Raise vehicle on ramp.
2.Rotate access panel anti-clockwise to release
locking flanges.
3.Remove access panel from undertray.
Refit
4.Locate access panel flanges in undertray
apertures.
5.Rotate panel clockwise to secure in undertray.
6.Lower ramp.