window LAND ROVER DEFENDER 1996 Workshop Manual

76CHASSIS AND BODY
2
REPAIR DOOR TRIM CASING
Service repair no - 76.34.01 - Front doors
Service repair no - 76.34.04 - Rear doors
Remove
1.Prise open finisher caps, remove 2 screws, and
detach door pull.
2.Remove single screw behind remote control
lever.
3.Prise off remote control lever bezel.
4.Prise off door locking button bezel.
5.Prise out window regulator handle centre
finisher, remove retaining screw, and withdraw
handle and bezel.
6.Using a screwdriver to release trim fasteners,
carefully ease trim casing from door.

CHASSIS AND BODY
3
REPAIR
Refit
7.Remove any trim fasteners held in door panel.
Refit or insert new clips to trim panel.
8.Ensure that anti-vibration pads are in position
and offer-up trim casing to door. Align fasteners
with holes in door and firmly push trim into
position.
9.Fit bezels to locking button and remote control
lever.
10.Fit single screw behind remote control lever.
11.Fit door pull and secure with 2 screws and
finisher caps.
12.Fit window regulator handle and retain with
single screw and finisher.WINDOW REGULATOR - REAR SIDE DOOR
Service repair no - 76.31.45
Remove
1.Remove door trim casing
See Door trim casing
.
2.Remove plastic sheet.
3.Temporarily fit handle, wind window up to its
fullest extent and support glass with a length of
timber, to prevent it falling when removing
regulator.
4.Remove 4 screws retaining regulator to
mounting panel and withdraw regulator whilst
sliding lifting arm button from lifting channel. To
assist this operation, remove timber and lower
glass.

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7
REPAIR DOOR GLASS - REAR SIDE DOOR
Service repair no - 76.31.02
Remove
1.Disconnect door check rod from door post.
2.Remove door trim casing
See Door trim casing
.
3.Remove plastic sheet.
4.Remove window regulator assembly
See
Window regulator - rear side door
.
5.Disconnect and remove door sill locking button
See Sill locking button.
6.Disconnect control rods from latch and door
outer handle mechanism.
7.Remove 4 screws retaining mounting panel to
door and remove panel, complete with rods and
control lever.
8.Remove single self tapping screw to remove
water channel.
9.Remove 2 screws and remove door check
torsion bar.
10.Remove door check rod by bending back end
stop to enable rod to be withdrawn.

76CHASSIS AND BODY
8
REPAIR
11.Remove 2 self-tapping screws from each side
and remove glass lower channels.
12.Remove inner and outer weather strips from
door sill.
13.Lower glass down to bottom of door, lift glass
over lower edge and withdraw from door.
14.Remove lift channel from glass, if necessary.Refit
15.Fit lift channel to new glass, if necessary.
16.Insert glass into lower channels and carefully
push glass up to top of frame.
17.Secure lower channels with 4 self-tapping
screws. Ensure that screw heads are screwed
down firmly below bottom of channels to prevent
damage to glass.
18.Fit door check rod and bend end stop back to
closed position.
19.Fit check stop torsion bar and secure with 2 nuts
and bolts.
20.Fit water channel and secure with single
self-tapping screw.
21.Fit mounting panel complete with rods and
remote control lever.
22.Connect control rods to latch and door outer
handle mechanism.
23.Fit door sill locking button and connect control
rod
See Sill locking button.
24.Fit window regulator
See Window regulator.
25.Fit door inner and outer sill wear strips.
26.Fit and re-seal plastic sheet.
27.Fit door trim casing
See Door trim casing.
28.Connect door check rod to door post.

CHASSIS AND BODY
9
REPAIR MOUNTING PANEL - FRONT DOOR
Service repair no - 76.11.28
Remove
1.Remove door trim casing
See Door trim
casing
and plastic sheet.
2.Remove 4 screws securing window regulator to
mounting panel.
3.Remove 5 screws securing mounting panel to
door frame.
4.Release remote control lever rod from latch
mechanism and from plastic clip in mounting
panel.
5.Slide window regulator arm from mounting panel
channel and remove panel with remote control
lever and rod.
Refit
6.Engage window regulator arm in mounting panel
channel.
7.Connect remote control rod to latch mechanism
and secure with clip.
8.Fit mounting panel and retain with 5 screws.
9.Secure window regulator to mounting panel with
4 screws.
10.Raise and lower window to check for free
movement.
11.Fit plastic sheet, and door trim casing
See
Door trim casing
.

76CHASSIS AND BODY
10
REPAIR SILL LOCKING BUTTON - FRONT DOOR
Service repair no - 76.37.29
Remove
1.Remove door trim casing
See Door trim
casing
.
2.Peel back sufficient of plastic sheet to expose
mechanism.
3.Release spring clip and disconnect operating rod
from latch mechanism.
4.Remove 2 screws and withdraw locking button
assembly.
Refit
5.Secure locking button assembly to door with 2
screws.
6.Connect operating rod to latch mechanism and
secure with spring clip.
7.Re-seal plastic sheet and fit door trim casing
See Door trim casing.WINDOW REGULATOR - FRONT DOOR
Service repair no - 76.31.45
Remove
1.Remove door trim casing
See Door trim casing
.
2.Remove plastic sheet.
3.Temporarily fit handle, position window half open
and support with a length of timber.
4.Remove 2 lower screws securing mounting
panel to door and slacken 3 upper screws.
5.Remove 4 screws retaining window regulator to
mounting panel and slide operating arms from
channels attached to glass and mounting panel
and remove regulator.
Refit
6.Insert regulator operating arms into channels.
7.Fit and tighten mounting panel lower screws and
tighten upper screws.
8.Position holes in regulator to line-up with holes in
mounting panel and secure with 4 screws.
9.Temporarily fit regulator handle and check that
glass can be raised and lowered without tight
spots.
10.Secure plastic sheet.
11.Fit door trim casing
See Door trim casing.

CHASSIS AND BODY
13
REPAIR LATCH ASSEMBLY - FRONT DOOR
Service repair no - 76.37.12
Remove
1.Remove mounting panelSee Mounting panel
and support glass with timber.
2.Disconnect control rod from handle operating
lever.
3.Disconnect control rod from locking lever on
handle.
4.Disconnect locking button control rod from latch
mechanism.
5.Remove 2 screws and remove handle assembly
from door.
6.Remove 2 self-tapping screws retaining lower
end of window glass runner.
7.Remove 3 screws securing latch assembly to
door.
8.Whilst taking care not to damage runner, ease
runner away from latch and manoeuvre latch
assembly from door.
Refit
9.Carefully ease window runner away, sufficiently
to enable latch to be located into position.
10.Secure latch to door with 3 screws.
11.Secure window runner with 2 screws ensuring
that packing strip is in position and that screw
heads are below bottom of runner to prevent
damage to glass.
12.Fit handle with 2 screws, ensuring that bezels
are in position.
13.Connect control rod to handle operating lever
and secure with spring clip.
14.Connect control rod to locking lever and retain
with spring clip.
15.Connect locking button control rod to latch lever
and secure with spring clip.
16.Fit mounting panel
See Mounting panel.

76CHASSIS AND BODY
14
REPAIR DOOR GLASS - FRONT DOOR
Service repair no - 76.31.01
Remove
1.Remove mounting panel
See Mounting panel
- front door
.
2.Remove window regulator.
3.Push glass up to top of its travel and support
with a suitable length of timber.
4.Remove 2 self tapping screws securing window
glass runner on latch side of door and single
screw from hinge side.
5.Taking care not to damage paint, prise exterior
waist weather strip from door.
6.Remove timber support and lower glass to
bottom of door.
7.Ease runner from glass at hinge side of door, lift
glass over bottom edge of door and withdraw.

CHASSIS AND BODY
15
REPAIR
Refit
8.Insert glass into runners at an angle as
illustrated.
9.Whilst lifting glass, position it squarely in
runners, raise to top of travel and insert timber
support.
10.Secure hinge side runner with single screw
ensuring that packing strip is in position.
11.Locate packing strip and secure opposite runner
with 2 screws. Ensure that all 3 screw heads are
well below bottom of runners to prevent damage
to glass.
12.Locate regulator in window lift channels.
13.Fit mounting panel
See Mounting panel - front
door
.LOCKING BARREL - FRONT DOOR
Service repair no - 76.37.39
Remove
1.Remove door trim casing
See Door trim
casing
and plastic sheet.
2.Remove mounting panel
See Mounting panel
- front panel
.
3.Raise and support glass to gain access to latch
mechanism.
4.Release spring clip and disconnect rod from lock
operating lever.
5.Remove single screw and withdraw lock lever
assembly.
6.Withdraw lock barrel from exterior door handle
complete with locking sleeve.

CHASSIS AND BODY
21
REPAIR REV: 05/99 Refit
8.Secure seat belt straps to floor mounting.
Tighten bolt to
32 Nm (24 lbf/ft)and fit finisher
cap.
9.Feed belt straps between seat cushion and
squab.
10.Fit inertia reel to 'C' post. Tighten bolt to
32 Nm
(24 lbf/ft).
11.Fit side trim panelSee Side trim panel.
12.Fit rear inward facing seats
See Rear seat
squab - 90
orSee Rear bench seat.SIDE TRIM PANEL - 90 STATION WAGON
Service repair no - 76.13.70
Remove
1.Remove rear seat squabs
See Rear seat
squab
.
2.Remove rear end trim panel
See Rear end
trim panel
.
3.Prise cap from front seat belt upper guide
retaining bolt.
4.Unscrew retaining bolt and remove seat belt
from 'B' post.
5.Carefully prise trim stud from 'B' post.
6.Remove 4 bolts securing side trim panel to body
side.
7.Release top edge of side trim panel by striking
upwards with the hand to disengage 3 spring
clips.
8.Lift trim panel from window surround and remove
from vehicle.