Land Rover Defender 90 110 Workshop Book 5 Rover
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1 ELECTRICAL 186) I* t:!; - Armature 33. Commutator end bracket; thread a & Whitworth or suitable similar tap firmly into the bush. Extract the bush with the tap using a power press in reverse. NOTE: Soak new bushes in engine oil for thirty minutes before fitting. , .I- 27. Check the armature insulation using suitable test equipment. Connect the tester between any one commutator segment and the shaft. The method illustrated uses a 110 V, 15 W test lamp. If the lamp illuminates the armature is faulty, and a replacement component is required. Reassembly 34. Reverse the instructions 1 to 22. Smear the teeth and operating collar of the roller clutch with Shell Retinax A grease. Smear the pivot lever of the drive assembly with Mobil 22 grease. Smear the drive shaft sun and planet gears with Rocol BRB1200 grease. 35. Tighten all the fixings to the correct torque - see 15w 11ov - Torque Wrench Settings. RRl927E 28. If necessary, the commutator may be machined, providing a finished surface can be obtained without reducing the diameter below 28.8 mm (1.13 in), otherwise a new commutator must be fitted. Finish the surface with fine emery cloth. Do not undercut the insulation slots. Drive assembly 29. Test the roller clutch. The pinion should rotatc in one direction only, independent of the clutch body. Replace the unit if unsatisfactory or if teeth are damaged or worn. Bearings 30. Renew the bearing bushes if there is evidence of armature fouling magnets or if there is perceptible side play between the shaft and bush. 31. Drive endhtermediate end bracket: press out the bush using a suitable press and mandrel. 32. Press the new bush in, ensuring that on the drive end bracket, the bush is flush with the casting. .. s:. ;.. . . .. . 47
186 I ELECTRICAL EQUIPMENT- LAMPS REMOVE AND OVERHAUL HEADLAMPS Remove and dismantle NOTE: Instructions 1 to 8 cover renewal of the bulb or light unit only. 1. Disconnect the battery for safety. 2. Remove the six screws and remove the plastic bczel 3. Remove the three screws retaining the rim and 4. Withdraw the light unit or reflector and pull-off the 5. Remove the rubber grommet. 6. Discard the light unit, if faulty, or the bulb if failed. 7. Release the spring clip to remove the bulb from the surrounding the head, side and flasher lamps. light unit, and remove the rim. electrical connector. ST1839M reflector unit. and secure with the spring clip, as illustrated. 9. Remove the four screws and release thc headlamp 10. Disconnect the electrical leads from the bullet 11. Remove the rubber seal. 12. Release the two trimmer screws and coil spring and detach the rim seating from the hcadlamp shell. 8. If required, fit a ncw bulb of the correct wattage shell from thc front wing. connectors and remove the headlamp shell. ST 1837M 48
ELECTRICAL EQUIPMENT- LAMPS 86 . Assemble and refit 13. Fit the rim seating to the headlamp shell with the two trimmer screws and coil spring. 14. Fit the rubber scal to the headlamp shell. 15. Conncct thc leads to the bullet connectors. 16. Fit the headlamp shell into the front wing locating the trimmer screws into the two holes in the wing. Ensure that thc assembly is located, as illustrated, with one trimmer screw at the 12 o’clock position and the other 90” to the Icft. 17. Secure the shell assembly to the wing with the four screws. 18. Offer-up the light or reflcctor unit to the rim seating and connect the electrical plug. 19. Secure the assembly with the rim and three screws. 20. Fit the plastic bezel with the six screws. 21. Connect the battery and check that the lamps function. 22. Check the main beam setting using bcam setting equipment. Should this not be available the beam can be temporarily checkcd and adjusted in the following way:- 23. Position the vehicle on level ground with the tyres correctly inflated, approximately four meters from a wall or screen, marked as illustrated. 24. The beam centres ‘A’ are measured horizontally on the vehicle and the dimension ‘B’ vertically from the ground. I B _.,_ I ,, ST1719M 25. Switch-on the main beam and adjust thc setting as necessary with thc trimmcr screws. 15. ST1918M ST1840M /’ 13 .._, .. 49
ELECTRICAL EQUIPMENT- LAMPS SIDE, TAIL AND FLASHER LAMPS Renew bulbs and lamps 1. Disconnect the battery. 2. Remove the two screws and fibre washers and withdraw the lens and collect the two rubber washers inside the lens. 3. Push the bulb inwards, twist and withdraw. 4. Remove the three screws and withdraw the lamp holder complete. Disconnect the electrical leads from the bullet connectors inside the vehicle wing for the front lamps. For rear lamps remove the cover inside the body for access to the connectors. 5. If necessary remove the rubber bulb holder cover. 5 I REAR NUMBER PLATE LAMP Remove and renew bulbs 1. Disconnect the battery and remove the single screw 2. At this stage the bulbs only can be renewed. 3. Disconnect the electrical leads. 4. Remove the cover from inside the vehicle body. 5. Remove the two nuts and washers securing the 6. Remove the bulb holder complete with rubber seal securing the lamp cover and lens. lamp to the vehicle body. and mounting block. ST1841M Refitting lamp and bulbs 6. Fit the rubber cover to the lamp holder. 7. Ensure that the drain gap in the cover is at the 8. Connect the electrical leads to the bullet 9. Fit the lamp to the vehicle, observing instruction 7, bottom. connectors. and secure with the three screws. 10. Fit the bulb of the same wattage, if renewed. 11. Fit the lens ensuring that the rubber and fibre washers are corrcctly positioned. Evenly tighten the two screws. Overtightening could crack the lens. Refitting lamp and bulbs 7. Assemble the bulb holder and rubber seal to the mounting block, connect the leads and fit to the vehicle body with the two screws and nuts. 8. Fit the bulbs. rf. 9. Fit the lens and lamp cover and secure with the single screw. Connect the battery and test the lamp. *- 50
ELECTRICAL EQUIPMENT - LAMPS Renew the bulbs 86 1. Disconnect thc battery. 2. Remove two screws and withdraw the warning light module from the front of the instrument panel. 3. Pull off the plug connector to give access to warning light bulbs. 4. Twist the bulb holder and pull it from its socket. 5. Pull the bulb from the holder. 6. Fit a new bulb and refit the holder and plug connector. 7. Refit the module. 8. Connect the battery. ... . . I !k-k-i! 2 ST 1919M INSTRUMENT ILLUMINATION Renew bulbs 1. Disconnect the battery. 2. Remove the four screws rctaining the instrument 3. Ease forward the panel to gain access to the bulbs. panel. If necessary, disconnect the drive cable from the back of the speedometer. 4. Twist the bulb holder and pull it from its socket. 5. Pull the bulb from its holder. 6. Fit a new bulb and refit the holder. 7. Replace the instrument panel. 8. Connect the battery. ST 1920M 51
86 OVERHAUL WIPER MOTOR ELECTRICAL EQUIPMENT- WIPER MOTOR DISMANTLE 1. Removc :hc wiper motor and drive from the 2. Remove the wiper motor gearbox cover. 3. Remove the circlip and plain washer securing the 4. Withdraw the connecting rod. 5. Withdraw the flat washer. 6. Remove the circlip and washer securing the shaft 7. Clean any burrs from the gear shaft and withdraw 8. Withdraw the dished washer. 9. Add alignment marks to the yoke and gearbox for vehicle. connecting rod. and gear. the gear. reassembly. 10. Remove the yoke securing bolts. 11. Withdraw thc yoke and armature. 12. Remove the brush gear assembly. 13. Remove the limit switch. 16. Test the armature for insulation and open - or short-circuits. Use a 110 V 15 W test lamp. Fit a new armature if faulty. 17. Examine the gear wheel for damage or excessive wear. ASSEMBLE Use Ragosine Listate Grease to lubricate the gear wheel teeth, armature shaft worm gear, connecting rod and pin, cable rack and wheelbox gear wheels. Use Shell Turbo 41 oil sparingly to lubricate the bearing bushes, armature shaft bearing journals, gear wheel shaft and wheelbox spindles. Thoroughly soak the felt washer in the yoke bearing with oil. 18. Fit the limit switch. 19. Fit the brush gear assembly. INSPECTION AND TEST 14. Check the brushes for excessive wcar, if they are worn to 4,8 mm (0.190 in) in length, fit a ncw brush gear asscmbly. 15. Using a push type gauge, check that the brush spring pressure is 140 to 200 g (5 to 7 02) when the bottom of the brush is level with the bottom of the slot in the brush box. Fit a new brush gear assembly if the springs are not satisfactory. KEY TO MOTOR COMPONEN1’S 1. Flexible drive 2. Gearboxcover 3, 4. Connecting-rod 5. Flat washer 6. Gear shaft retaining washer and circlip 7. Drivegcar 8. Dished washer 9. Alignment marks -yoke to body retaining washer and circlip 10. Yoke securing bolts 11. Armature and yoke 12. Brush gear assembly 13. Limit switch 1 ST1303M 52
ELECTRICAL EQUIPMENT- WTPER MOTOR 20. Fit the armature and yoke to gearbox using 28. To adjust the armature shaft end-float, hold the yoke vertically with the adjuster screw uppermost. Carefully screw -in the adjuster until resistance is felt, then back -off one quarter turn. alignment marks, secure with the yoke retaining bolts tightening to 23 Kg f cm (20 Ibf in). If a replacement armature is being fitted slacken the thrust screw to provide end-float for fitting the yoke. 21. Fit the dished washer beneath the gear wheel with the concave side towards the gear wheel. 22. Fit the gear wheel to the gearbox. 23. Secure the gear wheel shaft with the plain washer 24. Fit the larger flat washer over the crankpin. 25. Fit the connecting rod and secure with the smaller 26. Fit the gearbox cover and secure with the rctaining 27. Connect the electrical leads between the wiper and circlip. plain washer and circlip. screws. motor and limit switch. DATA Windscreen wiper motor Armature end -float ........................................... 0,l to 0,2 mm (0.004 to 0.008 in) Brush length, minimum ......................................... 4,8 mm (0.190 in) Brush spring tension. ............................................ 740 to 200 g (5 to 7 02) Resistance of armature winding at 16°C (69°F) measured between adjacent commutator segments.. .... Light running, rack disconnected: Current at 13.5 V .... 0.23 to 0.35 ohms 2.0 amps 45+ 3 rev/min 65.+ 5 rev/min Speed, 60 seconds from cold -Low speed.. ............... -High speed. ............... 53
ELECTRICAL EQUIPMENT- FAULT TRACING ELECTRICAL EQUIPMENT FAULT TRACING INTRODUCTION The following information is designed to assist electricians in diagnosing faults by a process of elimination. If the diagnosis charts are followed step by step, isolation of a fault and its rectification will be achieved logically and consistently in the minimum of time. Basic information on the use of standard equipment and normal workshop practice is not given. If electronic diagnostic equipment is being used, the manufacturers operating instructions must be followed. SYSTEMATIC DIAGNOSIS Normally, if the tests are completed in the sequence given, it should be possible to detect the fault. If difficulty is experienced, return to the beginning and analyse the results to check that you are on the right path. * 1. Collect Evidence Collect as much evidence as possible, do not rely on just a few symptoms. Use all the senses - sight, smell, sound. 2. Analyse Evidence Consider all evidence collected. 3. Locate Fault Narrow down the fault to a component, using test equipment and the collected evidence. 4. Determine and Remove Cause Ask why the fault has occurred. Trace and rectify the cause. 5. Rectify Fault Adjust, overhaul or renew the faulty component, but ensure the cause of the fault is also rectified. 6. Check System Ensure the equipment operates correctly and is properly fixed. PRELIMINARY CHECKS AND TESTS The checks and test procedures given must be carried out in the sequence indicated. Battery State of charge and condition of the battery must be checked before circuits are tested. Connections Ensure all connections are clean and secure. Earth connections must be made to clean unpainted surfaces. 54 Fuses Check for obvious signs of overload or short circuit before renewing a blown fuse or resetting an overload cut -out. Under no circumstances must a higher rating fuse be used than that specified. Voltage Drop Check a circuit with the normal load applied and the voltmeter connected in parallel. Voltage drop varies with load, cable size and current, Current Flow Connect the ammeter in series with the supply cable (not starter cable). Resistance Use an ohmmeter to measure the resistance in a circuit or component. Required Test Equipment Charging Tests 1 to 9 0 - 20 V Moving coil voltmeter 5-0-50 A Moving coil ammeter Hydrometer Heavy discharge voltage tester Cadium sticks Ignition Tests 10 to 15 0 - 20 V Moving coil voltmeter 0 - 1 V Moving coil voltmeter Ohmmeter Starter Tests 16 to 26 0 - 20 V Moving coil voltmeter 5-0-60 A Moving coil ammeter Hydrometer Lock torque clamps Spring balance ABBREVIATIONS A. Amperes L.T. Low tension Ah Ampere -hour mm Millimetre C d.c. Direct current v. Volts F Fahrenheit H.T. High tension % Percentage in Inch Centigrade (Celsius) rev/min revolutions per minute 0 Degree temperature
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ault Check Test attery not being charged AUTION: The vehicle attery must never be isconnected while the mgine is running iarning light stays on Varning light does not function then ignition switched on Rectification 1,293949 5 (ii) Ammeter reading below 10A, voltmeter reading between 13.6 and 14.6 V and battery in low state of charge (iii) (iv) Ammeter reading above 10A, voltmeter reading above 14.6V 6. Drive belt: Check the drive belt is not broken or slipping Ammeter reading below IOA, voltmeter reading below 13.6V rEST EQUIPMENT roltmeter 0 - 20 V moving coil immeter 5-0-60A moving coil fydrometer Bench test and overhaul Renew voltage regulator Renew voltage regulator Adjust or renew IGNITION SYSTEM 7. INDlead: Disconnect the IND lead from the alternator, start engine and run above idle speed. (i) Warning light stays on - Short circuit to earth between IND lead and warning light (ii) Warning light goes out 8. \Varning light bulb: Check warning lamp bulb (i) Bulb faulty (ii) E3ulb not faulty 9. Alternator plug connections: Remove plug from alternator, switch on ignition and connect a voltmeter between earth and each terminal in turn. (i) Voltmeter reads 12V Engine will not tire 10,11,12,13, 14,l Repair or renew Carry out Test 5 Renew Carry out Test 9 Carry out Test 5 10. Engine cranking speed: Too low 11. Sparking plugs: Check for dirty electrodes or incorrect gaps for faulty operation on pressure test equipment 12. Contact breaker points: Check for incorrect gap, burning or pitting 5. Alternator output Connect a voltmeter across the battery terminals. Connect an ammeter into the alternator battery sensing circuit either at the battery terminal or solenoid. Switch on all loads (except wipers) for one minute. Run the engine at 3,000 revlmin and wait until the ammeter reading is stable. (i) Ammeter reading Zero -Faulty alternator See STARTING SYSTEM Clean. set gaps or renew contact breaker distributors carry out Test 12 Clean, adjust or renew Overhaul alternator (ii) Voltmeter does not read 12V-cable circuits faulty Check cable continuity; repair or renew ~ 13. Distributor cap: Check for tracking (thin lines of burned bakelite), ensure cap is clean and dry and that the centre brush moves freely with no excessive side movement and contacts the rotor arm. Rectify or replace. Carry out Test 14. Rectify or replace. Carry out Test 14. continued