1996 LAND ROVER DEFENDER seats

GENERAL FITTING REMINDERS
1
INFORMATION GENERAL FITTING REMINDERS
WORKSHOP SAFETY IS YOUR RESPONSIBILITY!
The suggestions, cautions and warnings in the
section are intended to serve as reminders for
trained and experienced mechanics. This manual
is not a definitive guide to automotive mechanics
or workshop safety.
Shop equipment, shop environment, and the use
and disposal of solvents, fluids, and chemicals
are subject to government regulations which are
intended to provide a level of safety. It is your
responsibility to know and comply with such
regulations.
PRECAUTIONS AGAINST DAMAGE
1.Always fit covers to protect fenders before
commencing work in engine compartment.
2.Cover seats and carpets, wear clean overalls
and wash hands or wear gloves before working
inside vehicle.
3.Avoid spilling hydraulic fluid or battery acid on
paint work. Wash off with water immediately if
this occurs. Use Polythene sheets to protect
carpets and seats.
4.Always use a recommended Service Tool where
specified.
5.Protect temporarily exposed screw threads by
replacing nuts or fitting plastic caps.SAFETY PRECAUTIONS
1.Whenever possible, use a lift when working
beneath vehicle, in preference to jacking. Chock
wheels as well as applying parking brake.
WARNING: Do not use a pit when
removing fuel system components.
2.Never rely on a jack alone to support vehicle.
Use axle stands carefully placed at jacking
points to provide rigid support.
3.Ensure that a suitable form of fire extinguisher is
conveniently located.
4.Check that any lifting equipment used has
adequate capacity and is fully serviceable.
5.Disconnect battery.
WARNING: Do not disconnect any pipes in
air conditioning system, unless trained
and instructed to do so. A refrigerant is
used which can cause blindness if allowed to
contact eyes.
6.Ensure that adequate ventilation is provided
when volatile degreasing agents are being used.
7.Do not apply heat in an attempt to free stiff
fixings; as well as causing damage to protective
coatings, there is a risk of damage to electronic
equipment and brake linings from stray heat.

MAINTENANCE
1
MAINTENANCE SERVICE SCHEDULE
The following section describes the items detailed in
the vehicle Service Schedule. Where required
instructions are given for carrying out the service
procedure, or a cross reference is given to the section
in the manual where the procedure may be found.
Service Maintenance Schedules are published
separately to reflect the needs and intervals for each
vehicle variant. Procedures in the Workshop Manual
must be used in conjunction with the Service
Schedule sheets.
Service Maintenance Schedules are available from:
Land Rover Publications,
Character Mailing,
Heysham Road,
Bootle,
Merseyside, L70 1JL
VEHICLE INTERIOR
CHECK SEATS & BELTS
Check condition and security of seat belts, seat belt
mountings, seat belt buckles and operation of inertia
seat belts.
CHECK OPERATION OF LAMPS
Check operation of all lamps, horns and warning
indicators.
CHECK OPERATION OF WIPERS
Check operation of front/rear wipers and washers and
condition of wiper blades.CHECK OPERATION OF HANDBRAKE
Handbrake check/adjust
1.Chock road wheels.
2.Raise one rear wheel clear of ground and
support securely with axle stand.
3.Release handbrake lever.
4.Underneath vehicle, tighten adjuster bolt
clockwise to
25 Nm (18 lbf/ft)to fully lock brake
drum.
5.Slacken adjusting bolt by 1.5 turns to give brake
shoes running clearance. Check that the drum is
free to rotate.
6.Adjust handbrake cable locknuts to give pawl
two notches free movement on the rachet before
being fully operational on third notch of rachet.
NOTE: Cable adjustment must ONLY be
used for initial setting and to compensate
for cable stretch. It MUST NOT be used to
take up brake shoe wear, which MUST be adjusted
at brake drum.
7.Operate handbrake to settle brake shoes.
Recheck handbrake is fully operational on third
notch of rachet pawl. Readjust if necessary.
8.Remove axle stand and wheel chocks.

WHEELS AND TYRES
5
REPAIR Off Vehicle Balancing
Balance wheel assembly referring to equipment
manufacturer's instructions.
It is essential that the wheel is located by the centre
holeNOTthe stud holes. To ensure positive wheel
location the diameter of the locating collar on the
machine shaft must be 112,80 to 112,85 mm (4.441 to
4.443 in). This diameter will ensure that the collar fits
correctly within the centre hole of the wheel.
Where possible, always use the vehicle wheel
retaining nuts to locate the wheel on the balancer, to
avoid damaging the wheel. If this is not possible, the
locating nuts must be of a similar pattern to the
original wheel nuts. The use of conical type wheel
nuts for this purpose may damage the surface on alloy
wheels.
Cleaning
Wash the aluminium wheels using a suitable wash
and wax concentrate, correctly diluted and rinse with
cold clear water.DO NOTuse abrasives or aluminium
wheel cleaners containing acid, as they will destroy
the lacquer finish.
Tyre changing
Use only tyre changing equipment to mount or
demount tyres, following the equipment
manufacturer's instructions.DO NOTuse hand tools
or tyre levers, as they may damage tyre beads or the
wheel rim.
Puncture repair
Remove punctured tyre from wheel and repair using a
combination service plug and vulcanising patch.
Always follow manufacturer's instructions when using
a puncture repair kit.
Only punctures in tread area are reparable,DO NOT
attempt to repair punctures in tyre shoulders or
sidewalls.
Do not attempt to repair a tyre that has sustained the
following: bulges or blisters, ply separation, broken or
cracked beads, wear indicators visible and punctures
larger than 6 mm diameter.
CAUTION: Do not use tyre sealants that
are injected through valve stem to repair
punctured tyres, they may produce wheel
corrosion and tyre imbalance.
Aluminium wheel rim bead seats should be cleaned
using a non-abrasive cleaner to remove the mounting
lubricants and old rubber. Before mounting or
demounting a tyre, bead area should be well
lubricated with a suitable tyre lubricant.
TYRE FITTING
Alloy wheels
1.Install a new valve assembly.
2.Ensure wheel and tyre is adequately lubricated.
3.Mount tyre in normal manner. Inflate tyre and at
same time apply hand pressure to area around
valve to aid seating over valve first.
NOTE: Stop inflation immediately if tyre
seats opposite valve, as this will result in
valve being blocked by tyre beading,
making further inflation impossible, and carry out
following procedure.
4.Deflate tyre, unseat and rotate it around the rim
until valve is in line with that part of tyre which
seated initially. This part of beading having
seated over hump previously will automatically
seat first when tyre is re-inflated.
5.Inflate tyre to seat beads correctly, finally inflate
to correct pressure.

76CHASSIS AND BODY
20
REPAIR REAR SEAT BELTS - 90/110 STATION WAGON,
INWARD FACING SEATS
Service repair no - 76.73.18
Remove
1.Release belt straps from buckles.
2.Release stowage straps and lower both seat
cushions.
3.Unscrew bolt securing lap strap to body
mounting.
4.Remove lap strap, wavy washer, spacer and
plain washer.
5.Repeat operation for buckle strap.
Refit
6.Secure lap strap and buckle straps to body.
Tighten bolts to
32 Nm (24 lbf/ft).
7.If required, secure seat cushions and belts in
stowed position.REAR SEAT BELTS - 110
Service repair no - 76.73.18
Remove
1.Remove rear inward facing seats
See Rear
seat squab - 90
orSee Rear bench seat.
2.Remove side trim panel
See Side trim panel.
3.Remove bolt securing seat belt inertia reel to 'C'
post.
4.Remove seat belt assembly.
5.Pull seat belt straps between seat cushion and
squab into rear of vehicle.
6.Remove finisher cap and bolt securing seat belt
anchorage to floor.
7.Remove seat belt assembly.

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.

76CHASSIS AND BODY
22
REPAIR Refit
9.Fit new spring clips to the 3 brackets on top
edge of side trim panel.
10.Align trim panel, ensuring it is correctly
positioned around side window.
11.Locate trim panel spring clips on inner cant rail
and press firmly down to secure top edge of trim
panel.
12.Align bosses of trim panel with body side fixing
holes and secure with 4 bolts and washers. Do
not fully tighten at this stage.
13.Fit trim stud to secure bottom edge of trim panel
to 'B' post.
14.Secure seat belt guide to 'B' post, tighten bolt to
32 Nm (24 lbf/ft)and fit cap.
15.Fit rear end trim panel
See Rear end trim
panel
.
16.Fit rear seat squab
See Rear seat squab.SIDE TRIM PANEL - 110 STATION WAGON
Service repair no - 76.13.70
Remove
1.Remove rear inward facing seats
See Rear
seat squab - 90
,orSee Rear bench seat.
2.Remove rear end trim panel
See Rear end
trim panel
.
3.Prise finisher cap from rear seat belt upper guide
bracket retaining bolt.
4.Unscrew bolt and remove guide bracket from 'C'
post.
5.Remove bolt securing seat belt to wheel arch
mounting.
6.Prise trim panel cap fastener from 'C' post.
7.Remove seat belt aperture finisher from side trim
panel.
8.Remove screw and release seat belt clip from 'C'
post.

CHASSIS AND BODY
23
REPAIR
9.Remove fixings securing bottom edge of trim
panel to body side.
10.Release top edge of trim panel by striking
upwards with the hand to disengage 3 spring
clips.
11.Lift trim panel from window surround and feed
seat belt through panel aperture.
12.Remove trim panel from vehicle.
Refit
13.Fit new spring clips to the 3 brackets on top
edge of side trim panel.
14.Feed seat belt through aperture in trim panel and
fit finisher.
15.Align trim panel, ensuring it is correctly
positioned around side window.
16.Locate trim panel spring clips on inner cant rail
and press firmly down to secure top edge of trim
panel.
17.Align bosses of trim panel with body side fixing
holes and secure with bolts or screws. If
individual type seats are fitted do not fully tighten
fixings at this stage.
18.Fit seat belt clip to 'C' post.
19.Fit trim panel cap fastener to 'C' post.
20.Fit seat belt to wheel arch. Tighten bolt to
32 Nm
(24 lbf/ft).
21.Fit seat belt guide bracket to 'C' post. Tighten
bolt to
32 Nm (24 lbf/ft)and fit finisher cap.
22.Fit rear end trim panel
See Rear end trim
panel
.
23.Fit inward facing seats
See Rear seat squab,
or
See Rear bench seat.REAR END TRIM PANEL - 90/110 STATION
WAGON
Service repair no - 76.13.71
Remove
1.Pull edge of rear end trim panel firmly to release
2 spring retaining clips from vertical rail at door
aperture.
2.Remove rear end trim panel.
Refit
3.Fit new spring clips to the 2 brackets on side of
trim panel.
4.Position outboard edge of trim panel in corner to
abut side trim panel and locate spring clips on
vertical rail.
5.Press edge of trim panel firmly to secure in
position.

86ELECTRICAL
24
REPAIRREV: 05/99 HEADLAMP BEAM ALIGNMENT
Service repair no - 86.40.17
Check
Check main beam alignment using beam setting
equipment. Should this not be available the beam can
be temporarily checked and adjusted as follows:-
1.Position vehicle, unladen, on level ground with
tyres correctly inflated, approximately 4 metres
from a wall or screen, marked as illustrated
below.
2.The beam centres 'A' are measured horizontally
on the vehicle and dimension 'B' vertically from
the ground.
3.Switch on main beam and adjust setting, as
necessary, with trimmer screws.On vehicles fitted with headlamp levelling units, check
and adjust headlamp beam alignment as previously
described, with fascia mounted levelling switch at
position '0'. The headlamps can then be adjusted,
according to load conditions, as follows:-
Position '0' - Driver only, or driver and all front seats
occupied (loadspace empty).
Position '1' - All seats occupied (loadspace empty).
Position '2' - All seats occupied by adults and
loadspace loaded to maximum rear axle weight.
Position '3' - Driver only with loadspace loaded to
maximum rear axle weight.