1996 LAND ROVER DEFENDER lock

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.

76CHASSIS AND BODY
16
REPAIR 7.To remove barrel from plastic retaining sleeve,
depess spring loaded button and withdraw
sleeve.
Refit
NOTE: If a new barrel is being fitted, check
that number on barrel coincides with
number on accompanying key.
8.Push plastic retaining sleeve over barrel until
spring loaded peg locks it into position.
9.Fit barrel and plastic sleeve assembly to locking
sleeve and insert into exterior handle reversing
instruction 6.
10.Assemble lock lever components as illustrated
and from inside of door panel, fit them to barrel
assembly with single screw.
11.Connect operating rod to lock lever and secure
with spring clip, reversing instruction 4.
12.Fit mounting panel
See Mounting panel - front
door
.DOOR STRIKER - ADJUST
Service repair no - 76.37.23 - front door
Service repair no - 76.37.24 - rear door, 110/130
Adjust
1.Loosen 2 Torq bolts securing striker to body.
2.Adjust alignment of striker vertically and
horizontally, lightly tighten bolts.
3.Close door, check for correct latching with door
lock and for centering on striker.
4.Add or remove packing shims as necessary
behind striker and fully tighten bolts.
5.Carry out further adjustment as necessary. If full
adjustment is not achieved carry out the
following:
6.Remove striker and nut plate.
7.Elongate striker bolt holes in 'B' or 'C' post in
direction required.
8.Refit striker and adjust as necessary.

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.

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.

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.