Land Rover Defender 90 110 Workshop Book 5 Rover
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ELECTRONIC IGNITION - V8 ENGINE 186 I ELECTRONIC IGNITION - WITH 35DMS \.I I. .. e, ’ DISTRIBUTOR The Lucas model 35DM8 distributor has a conventional advancehetard vacuum unit and centrifugal automatic advance mechanism. A pick-up module, in conjunction with a rotating timing reluctor inside the distributor body, generates timing signals. These are applied to an electronic ignition amplifier unit fitted under the ignition coil mounted on top of the left front wing valance. Key to illustration I: Cap 2. HT Brush and spring 3. Rotorarm 4. Insulation cover (Flash shield) 5. Pick-up and base plate assembly 6. Vacuum unit 7. ‘0’ ring oil seal - I. RR458M 7
1861 ELECTRONIC IGNITION - V8 ENGINE DISTRIBUTOR - ELECTRONIC IGNITION - V8 ENGINES 35DM8 Remove and refit Removing 1. Disconnect battery. 2. Disconnect vacuum pipe(s). 3. Remove distributor cap. 4. Disconnect low tension lead from coil. 5. Mark distributor body in relation to centre line of rotor arm. 6. Add alignment marks to distributor and front cover. NOTE: Marking distributor enables refitting in exact original position, but if engine is turned while distributor is removed, complete ignition timing procedure must be followed. 7. Release the distributor clamp and remove distributor. Refitting NOTE: If a new distributor is being fitted, mark body in same reiative position as distributor removed. 8. Leads for distributor cap should be connected as illustrated. Figures 1 to 8 inclusive indicate plug lead numbers. RH - Right hand side of engine, when viewed from the rear. LH Left hand side of engine, when viewed from the rear. 8 RR616M 9. If engine has not been turned whilst distributor has been removed, proceed as follows (items 10 to 17). 10. Fit new 0 ring seal to distributor housing. 11. Turn distributor drive until centre line of rotor arm is 30 anti-clockwise from mark made on top edge of distributor body. 12. Fit distributor in accordance with alignment markings. NOTE: It may be necessary to align oil pump drive shaft to enable distributor drive shaft to engage in slot. 13. Fit clamp and bolt. Secure distributor in exact original position. 14. Connect vacuum pipe to distributor and low tension lead to coil. 15. Fit distributor cap. 16. Reconnect battery. 17. Using suitable electronic equipment, set ignition timing as follows. 18. If, with distributor removed, engine has been turned it will be necessary to carry out the follwing procedure. 19. Sct engine - No. 1 piston to static ignition timing figure (see section 05) on compression stroke. 20. Turn distributor drive until rotor arm is approximately 30 anti-clockwise from number one sparking plug lead position on cap. 3-1. Fit distributor to engine. 22. Check that centre line of rotor arm is now in line with number one sparking plug lead on cap. Reposition distributor if necessary. 23. If distributor does not seat correctly in fron cover, oil pump drive is not engaged. Engage by lightly pressing down distributor while turning engine. 24. Fit clamp and bolt leaving both loose at this stage. 25. Set the timing statically to within 2-3of T.D.C. 26. Connect vacuum pipe(s) to distributor. 27. Fit low tension lead to coil. 28. Fit distributor cap. 29. Reconnect battery. 30. Using suitable electronic equipment set thc ignition timing.
ELECTRONIC IGNITION - V8 ENGINE 186 I 1. It is essential that the following procedures are adhcrcd to. Inaccurate timing can lead to scrious engine damage and additionally create failurc to comply with the emission regulations applying to the country of destination. If the engine is being checkcd in the vehicle and is fitted with an air conditioning unit the compressor must be isolated. 2. On initial engine build, or if the distributor has been disturbed for any reason, the ignition timing must be set statically to within 2-3 of T.D.C. (This sequence is to give only an approximation in order that the engine may be started) ON NO ACCOUNT MUST THE ENGINE BE STARTED BEFORE THIS OPERATION IS CARRIED OUT. Refer to Engine Tuning Data for ignition timing specification. % Equipment required Calibrated Tachomctcr Stroboscopic lamp 3. Couple stroboscopic timing lamp and tachometer to engine following the manufacturcrs instructions. 4. Disconnect the vacuum pipes from thc distributor. 5. Start engine; with no load and not exceeding 3,000 rpm, run engine until normal opcrating temperature is reached. (Thermostat open). Check that the normal idling speed falls within the tolerance specificd in table. 6. Idle speed for timing purposes must not excccd 750 rpm, and this speed should be achieved by removing a breather hose, NOT BY ADJUSTING CARBURETTER IDLE SETTING SCREWS. 7. With the distributor clamping bolt slackened, turn distributor until the timing flash coincides with the timing pointer and the correct timing mark on the rim of the torsional vibration dampcr as shown in the table. 8. Retighten the distributor clamping bolt securely. Rccheck timing in the event that retightening has disturbed the distributor position. 9. Refit vacuum pipes. 10. Disconnect stroboscopic timing lamp and tachometer from engine. LUCAS CONSTANT ENERGY IGNITION SYSTEM 35DMS PRELIMINARY CHECKS Inspect battery cables and connections to ensure they are clean and tight. Check battery state of charge if in doubt as to its condition. Inspect all LT connections to ensure that they are clean and tight. Check the HT leads arc correctly positioned and not shorting to earth against any engine components. The wiring harness and individual cables should be firmly fastencd to prevent chafing. PICK-UP MODULE AIR GAP SETTINGS Air gap settings vary according to vehicle application. NOTE: The gap is set initially at the factory and will only require adjusting if tampered with or when the pick -up module is replaced. Test Notes (i) The ignition must be switched on for all chccks. (ii) Key to symbols used in charts for Tests 2. Correct High Low Reading Rcading Reading (iii) Use feeler gauges manufactu.red from a non- magnetic material when setting air gaps. TEST 1: Check HT Sparking Remove coiVdistributor HT lead from distributor cover and hold approximately 6 mm (0.25 in) from the engine block. Switch the ignition on and operate the starter. If regular sparking occurs, proceed to Test 6. If no sparking proceed to Test 2. Test 1 RR460M Crank engine 8 9
lzi ELECTRONIC IGNITION - FAULT DIAGNOSIS TEST 2: Test 2 Amplifier Static Checks Switch the ignition ‘ON’ (a) Connect voltmeter to points in the circuit indicated by the arrow heads and make a note of the voltage readings. NOTE: Only move the voltmeter positive lead during tests 2,3 and 4. (b) Compare voltages obtained with the specified EXPECTED READINGS 1 More than 11.5 volts 2 1 volt max below volts at point 1 in test circuit 3 1 volt max below volts at point 1 in test circuit 4 0 volt -0.1 volt (c) If all readings are correct proceed to Test 3. (d) Check incorrect reading(s) with chart to identify area of possible faults, i.e. faults listed under heading “Suspect”. - RR461Mv values listed below:- - TEST 3: 1 2 3 4 SUSPECT L v v v Discharged battery d L L v Ign. switch and/or wiring v v L d Coil or amplifier v v v H Amplifier earth Check Amplifier Switching Disconnect the High Tension lead between the coil and distributor. Connect the voltmeter between battery positive (+ ve) terminal and HT coil negative (- ve) terminal: the voltmeter should register zero volts. Switch the ignition ‘on’ and crank the engine: the voltmeter reading should increase just above zero, in which case proceed with Test 5. If there is no increase in voltage during cranking proceed to Test 4. Test 3 To ign switch RR462M 10 TEST 4: Pick-up Coil Resistance. Applications with Separate Amplifier Disconnect the pick-up leads at the harness connector. Connect the ohmmeter leads to the two pick -up leads in the plug. The ohmmeter should register between 2k and 5k ohms if pick-up is satisfactory. Change the amplifier if ohmmeter reading is correct. If the engine still does not start carry out Test 5. Change the pick-up if ohmmeter reading is incorrect. If the engine still does not start proceed to Test 5. e: e -5 > Test 4 A RR463M
ELECTRONIC IGNITION - FAULT DIAGNOSIS 186 L .,. . ..- ., TEST5: TEST 7: i ::. . \..;;:::;*Y . ,, , ,. ,. . .... .. ..-. Check HT Sparking Visual and HT Cable Checks .. .;,7.. ; .. . ... .,. I. , .. . . , , .. .. . .... . .. . Remove existing coil/distributor HT lead and fit test HT lead to coil chimney. Hold free end about 6 mm (0.25 in) from the engine block and crank the engine. HT sparking good, repeat test with original HT lead, if then no sparking, change HT lead. If sparking is good but engine will not start, proceed to Test 6. If no sparking, replace coil. If engine will not start carry out Test 6. Test 5 Crank TEST 6: Check Rotor Arm Remove distributor cover. Disconnect coil HT lead from cover and hold about 3 mm (0.13 in) above rotor arm electrode and crank the engine. There should be no HT sparking between rotor and HT lead. If satisfactory carry out Test 7. HT sparking, replace rotor arm. If engine will not start carry out Test 7. Test 6 Crank 9 engine //IF RR465M Q Examine: Should be: 1. Distributor Cover Clean, dry, no tracking marks 2. CoilTop Clean, dry, no tracking marks 3. HT Cable Insulation Must not be cracked chafed or perished 4. HT Cable Continuity Must not be open circuit 5. Sparking Plugs Clean, dry, and set to correct gap- NOTE: 1. Reluctor Must not foul pick-up or leads 2. RotorandFlash Must not be cracked or show Shield signs of tracking marks. I . ..- .. , ,,.! .,. ,. !, .. 11
I86 I ELECTRONIC IGNITION - V8 ENGINE OVERHAUL DISTRIBUTOR - LUCAS 35DM8 Distributor Cap 1. Unclip and remove cap. 2. Renew cap if known to be faulty. 3. Clean with a nap-free cloth. Rotor Arm 4. Pull rotor arm from keyed shaft. 5. Renew rotor arm if known to be faulty. Insulation Cover (Flash shield) 6. Remove cover, secured by 3 screws. 7. Renew cover if known to be faulty. Vacuum Unit 8. Remove 2 screws from vacuum unit securing bracket, discngage vacuum unit connecting rod from pick -up base plate connecting peg, and withdraw vacuum unit from distributor body. Re-Assem bly 14. This is mainly a reversal of the dismantling procedure, noting the following points: Lubrication Apply clean engine oil: (a) 3 drops to felt pad reservoir in rotor shaft. Apply Chevron SH1 (or equivalent) grease. (b) Auto advance mechanism (c) Pick -up plate centrc bearing (d) Pre tilt spring and its rubbing area (pick-up and (e) Vacuum unit connecting peg (pick-up and base (f) the connecting peg hole in vacuum unit Apply Rocal MHT (or equivalent) grease. (8) Vacuum unit connecting rod seal (located in base plate assy) assy) and connecting rod. vacuum unit where connecting rod protrudes) NOTE: Applicable only to double acting vacuum units. =, - 42- I -- ,, Pick-up and Base Plate Assembly 9. Use circlip pliers to remove the circlip retaining the reluctor on rotor shaft. 10. Remove the flat washer and then the 0 ring recessed in the top of the reluctor. 11. Insert the blade of a small screwdriver bcneath the reluctor and prise it partially along the shaft, sufficient to enable it to be gripped between fingers and withdrawn from the shaft. NOTE: Coupling ring fitted beneath reluctor. 12. Remove pick-up and base plate assembly, secured by 3 support pillars. NOTE: Do not disturb the 2 barrel nuts securing the pick -up module, otherwise the air gap will need re-adjustment. Fitting Pick-up and Base Plate Assembly 15. Pick up leads must be prevented from fouling the rotating reluctor. Both leads should be located in plastic carrier as illustrated. Check during re- assembly. 13. Renew pick-up and base plate assembly if module is known to be faulty, otherwise check pick -up winding resistance (2k-5k ohms). TECHNICAL DATA Firing angles ..................................................... 0-45-90 etc. ? 1 Appiicaiivn ....................................................... 1~. v iyGpiivG L11 (Pick up limbheluctor tooth) ................................. 0.20 mm - 0.35 mm (0.008 in - 0.014 in) 1?TI hl--,. *: .,,. ,...,I. Pick up air gap adjustment Pick up winding resistance .................................... 2k - 5k ohms 12
ELECTRONIC IGNITION - V8 ENGINE I86 I ,. * . ,. - Refitting Reluctor ELECTRONIC IGNITION - with Lucas 35DLMS Distributor * e.- 1 16. Slide reluctor as far as it will go on rotor shaft, then rotate reluctor until it engages with the coupling ring beneath the pick up base plate. The distributor shaft, coupling ring and reluctor are keyed and rotate together. Pick Up Air Gap Adjustment 17. The air gap between the pick up limb and reluctor teeth must be set within the specified limits, using a non -ferrous feeler gauge. NOTE 1: When the original pick up and base plate assembly has been refitted the air gap should not normally require resetting as it is pre -set at the factory. When renewing the assembly the air gap will require adjusting to within the gpecified limits. - . See technical data. .. .~ .. , I. AMPLIFIER Remove and Refit Removing The Lucas 35DLM8 distributor has a conventional advancehetard unit and centrifugal automatic advance mechanism. A pick-up module, in conjunction with a rotating timing reluctor inside the distributor body, generates timing signals. These are applied to an electronic ignition amplifier module mounted on the side of the distributor body. NOTE: The pick -up air gap is factory set. Do not adjust the gap unless the pick-up is being changed or the base plate has been moved. Use a non -ferrous feeler gauge to set the air gap. DISTRIBUTOR - 35DLM8 Remove and refit Removing 18. Disconnect the battery. 19. Disconnect the electrical lcads from the amplifier and coil. 20. Remove the two retaining bolts with washers securing the coil to the amplifier. 21. Remove the two bolts securine thc amdifier to the Disconnect battery. 2. Disconnect vacuum pipe(s). 3. 4. Disconnect low tension lead from coil. 5. Mark distributor body in relation to centre line of distributor cap. valance. rotor arm Refitting 22. Reverse the removal procedure, ensuring that all electrical leads are correctly reconnected. NOTE: The amplifier is not serviceable, in the event of a fault a new amplifier must be fitted. 6. Add alignment marks to distributor and front cover. 13
ELECTRICAL NOTE: Marking distributor enables refitting in exact original position, but if engine is turned while distributor is removed, complete ignition timing * procedure must be followed. 7. Release the distributor clamp and remove the distributor. Refitting NOTE: If a new distributor is being fitted, mark body in same relative position as distributor removed. 8. Leads for distributor cap should be connected as illustrated. Figures 1 to 8 inclusive indicate plug lead numbers. RH - Right-hand side of engine, when viewed from the rear. LH - Left-hand side of engine, when viewed from the rear. A @) y RR616M 9. If engine has not been turned whilst distributor has been removed, proceed as follows (items 10 to 17). 10. Fit new 0 ring seal to distributor housing. 11. Turn distributor drive until centre line of rotor arm is 30 anti-clockwise from mark made on top edge of distributor body. 12. Fit distributor in accordance with alignment markings. NOTE: it may be necessary to align oil pump drive shaft to enable distributor drive shaft to engage in slot. 14 13. Fit clamp and bolt. Secure distributor in exact orginal position. 14. Connect vacuum pipe to distributor and low tension lead to coil. 15. Fit distributor cap. 16. Reconnect battery. 17. Using suitable electronic equipment, set the ignition timing, See IGNITION TIMING - Adjust. 18. If, with distributor removed, engine has been turned it will be necessary to carry out the following procedure. 19. Set engine - No. 1 piston to static ignition timing figure (see data section) on compression stroke. 20. Turn distributor drive until rotor arm is approximately 30 anti-clockwise from number one sparking plug lead position on cap. 21. Fit distributor to engine. 22. Check that centre line of rotor arm is now in line with number one sparking plug lead on cap. Reposition distributor if necessary. 23. If distributor does not seat correctly in front cover, oil pump drive is not engaged. Engage by lightly pressing down distributor while turning engine. 24. Fit clamp and bolt leaving both loose at this stage. 25. Set the ignition timing statically to within 2-3 of T.D.C. 26. Connect the vacuum pipe to the distributor. 27. Fit low tension lead to coil. 28. Fit distributor cap. 29. Reconnect the battery. 30. Using suitable electronic equipment set the ignition timing, See IGNITION TIMING -Adjust. DISTRIBUTOR-LUCAS 35DLM8 Overhaul DISTRIBUTOR COVER 1. Unclip and remove the cover. 2. Renew the cover if known to be faulty. 3. Clean the cover and HT brush with a nap free cloth. ROTOR ARM 4. Pull rotor arm from keyed shaft. 5. Renew rotor arm if known to be faulty. INSULATION COVER (Flash shield) 6. Remove cover, secured by three screws. 7. Renew cover if known to be faulty. VACUUM UNIT 8. Remove two screws from vacuum unit securing bracket, disengage vacuum unit connecting rod from pick -up base plate connecting peg, and withdraw vacuum unit from distributor body.
ELECTRICAL AMPLIFIER MODULE 86 9. Remove two screws and withdraw the module. 10. Remove the gasket. 11. Remove two screws securing the cast heatsink and remove the heatsink. WARNING: The amplifier contains Beryllia. Do not open or crush. PICK -UP AND BASE PLATE ASSEMBLY 12. Use circlip pliers to remove the circlip retaining the 13. Remove the flat washer and then the ‘0’ ring 14. Gently withdraw the reluctor from the shaft, taking reluctor on rotor shaft. recessed in the top of the reluctor. 15 care not to damage the teeth. NOTE: Coupling ring fitted beneath reluctor. Remove three support pillars and cable grommet. Lift out the pick-up and base plate assembly. NOTE: Do not disturb the two barrel nuts securing the pick -up module, otherwise the air gap will need re -adjustment. 16. Renew pick-up and base plate assembly if module is known to be faulty, otherwise check pick-up winding resistance (2k -5k ohm). RE -ASSEMBLY 17. This is mainly a reversal of the dismantling procedure, noting the following points: LUBRICATION Apply clean engine oil: a. Threc drops to felt pad reservoir in rotor shaft. FITTING PICK -UP AND BASE PLATE ASSEMBLY 18. Pick-up leads must be prevented from fouling the rotating reluctor. Both leads should be located in plastic carrier as illustrated. Check during re- assembly. REFITTING RELUCTOR 19. Slidc reluctor as far as it will go on rotor shaft, then rotatc reluctor until it engages with the coupling ring beneath the pick-up base plate. The distributor shaft, coupling ring and reluctor are ‘kcycd’ and rotate together. Fit the ‘0’ ring, flat washcr and retaining circlip. PICK -UP AIR GAP ADJUSTMENT 20. The air gap between the pick-up limb and reluctor teeth must be sct within the spccified limits, using ;I non-ferrous feeler gauge. 21. If adjustmcnt is necessary, slacken the two barrel nuts to set the air gap. See Engine Tuning Data. Apply Chevron SR1 (or equivalent) grease. b. Auto advance mechanism. c. Pick -up plate centre bearing. d. e. f. Pre tilt spring and its rubbing area (pick-up and base plate assy). Vacuum unit connecting peg (pick -up and base plate assy) and the connecting peg hole in vacuum unit connecting rod. NOTE: When the originai pick -up and base plate assembly has been refitted the air gap should be When renewing the assembly the air gap will require adjusting to within the specified limits. checked, and sdjusted if?--------. I cLcn3ai y . 15
ELECTRICAL 1 Y .% I .L- I Y Service Parts 1. Cover 2. HT brush & spring 3. Rotor arm 4. Insul cover 5. Pick-up module and base platc asscmbly 6. Vacuum unit 7. Amplifier module 8. 0-ring oil scal 9 Gasket 16 W RRl866 E U