Land Rover Defender 90 110 Workshop 1984 Rover Manual
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ELECTRICAL EQUIPMENT ELECTRICAL PRECAUTIONS 86 The following guidelines are intended to ensure the safety of the operator whilst preventing damage to electrical and any electronic components fitted to the vehicle. Before commencing any test procedure on a vehicle ensure that the test equipment is working correctly and any harness or connectors are in good condition, this particularly applies to mains leads and plugs. WARNING: Before commencing work on an ignition system, all high tension terminals, adaptors and diagnostic equipment for testing should be inspected to ensure that they are adequately insulated and shielded to prevent accidental personal contacts and minimize the risk of shock. Wearers of surgically implanted pacemaker devices should not be in close proximity to ignition circuits or diagnostic equipment. L Polarity Never rcversc connect the vehicle battery and always observe the correct polarity when connecting test equipment. High voltage circuits Whenever disconnecting live high tension circuits always use insulated pliers and never allow the open end of a high tension lead to come into contact with other components particularly electronic control units. Exercise caution when measuring the voltage on the coil terminals while the engine is running, since, high voltage spikes can occur on these terminals. Connectors and harness Always ensure that thesc items are dry and oil free before disconnecting and connecting test equipment. Never forcc connectors apart either by using tools or by pulling on the wiring harness. Always ensure locking tabs are disengaged before removal and note orientation to enable correct reconnection. Ensure that any protective covers and substances are replaced if disturbed. Having confirmed a component to be faulty switch -off the ignition and disconnect the battery. Rcmove the component and support the disconnected harness. When replacing the component keep oily hands away from electrical connection areas and push connectors home until any locking tabs fully engage. Battery disconnecting , Before disconnecting the battery, switch off all electrical equipment. Battery charging Recharge the battery out of the vehicle and keep the top well ventilated. While being charged or discharged, and for approximately fifteen minutes afterwards, batteries emit hydrogen gas which is flammable. Always ensure any battery charging area is well ventilated and that every precaution is taken to avoid naked flames and sparks. GENERAL PRECAUTIONS Switch-off ignition prior to making any connection or disconnection in the system as clcctrical surge caused by disconnecting ‘live’ connections can damage electronic componcnts. Ensure hands and work surfaces are clcan and frcc of grease, swarf, etc. as grease collects dirt which can cause tracking or high-resistance contacts. When handling printed circuit boards, treat them as you would a hi-fi record - hold by thc edges only. Prior to commencing a test, and periodically during a test, touch a good earth, for instance, a cigar lighter socket, to discharge body static as some clcctronic components are vulnerable to static electricity. TEST EQUIPMENT A range of ‘Fast Check’ testers is available to provide a means of fast effective diagnosis of faults in electronic systems currently fitted to Land Rover and Range Rover vehicles. It is essential that operators familiarise themselves with the component> of the system to be checked and the instruction for the relevant fast check test before commencing diagnosis.
ELECTRICAL EQUIPMENT- V8 ENGINE DISTRIBUTOR OVERHAUL V8 ENGINE DISTRIBUTOR DISMANTLE 1. Unclip and remove the distributor cap. 2. Withdraw the rotor arm. 3. Remove the contact breaker spring anchor nut and lift off: a) the top -half of insulation bush b) the low tension lead (Black) c) the capacitor lead (Orange). 4. Remove the contact breaker retaining screw, plain and spring washer and remove contact set assembly . 5. Remove the complete insulation bush. 6. Remove the capacitor. 7. Remove the dwell-angle adjuster screw and spring. 8. Remove thc two screws and withdraw the vacuum unit and rubber joint washer. 9. Remove the three screws and lift off the centrifugal advance cover -plate with the cover plate earth lead. 10. Punch out the drive pinion roll-pin and remove the drive pinion and tab washer. . -,- INSPECTION 11. Examine the parts for wear and replace as necessary. Renew the capacitor and contact set. Examine the distributor cap for cracks and tracking. Renew the cap if the electrodes are worn and burned. If the cap is serviceable fit a new H.T. pick-up brush and spring. Renew the rotor arm if cracked and if the metal contact is burnt and worn. Check the low tension lead for continuity and rcnew if faulty. Check the vacuum unit diaphragm by withdrawing the air and placing a finger over the air pipe to determine if the vacuum is being held. Renew the unit if unsatisfactory. ASSEMBLE When assembling, smear the centrifugal cover-plate and vacuum lever with Chevron SR1 grease or equivalent. 12. Fit the tab washer and drive pinion and secure with --. l? a new roll pin. with the three screws noting that one screw is used to retain the centrifugal advance cover plate earth lead. 14. Fit the vacuum unit and rubber joint washer and ensure that the operating lever is inserted between the two plates which make up the centrifugal cover plate assembly. Fit the cefitrjfqz! a&..ncP, colJer-p!atP, 2nd Secure 2 15. Fit the dwell angle adjustment screw and spring. 16. Fit the capacitor. 17. Fit the contact breaker set ensuring that the small post protruding from below the contact set locates through the hole in the cover plate into the hole in the end of the vacuum unit actuating lever. Secure with the screw, plain and spring washers. 18. Assemble the contact breaker spring insulating bushes and electrical leads, as illustrated in thc following sequence: a) lower bush b) spring c) low tension lead d) capacitor lead e) top bush f) and secure with the anchor spring nut. cam lubrication pad. 19. Apply a few drops of engine oil to the distributor Sl e &-- a .il 20. Using a feeler gauge, and the dwell angle adjuster, set the contact breaker points to a nominal clearance of 0,35 to 0,40 mm (0.014 to 0.016 in). Once the distribute: is fitted te the engine the dwell angle must be adjusted to 26 to 28 using special tuning equipment. 21. Fit the rotor arm. 22. Fit the distributor cap ensuring that the H.T. c$ 23. When fitting the distributor to the engine insert a pick -up brush moves freely in its location. new 0 ring seal into the body groove.
.. . ... .. I .. .... d , . .... .. I. ..... .. ,,,. ., .. ., . ELECTRICAL EQUIPMENT- V8 ENGINE DISTRIBUTOR L 86 5 KEY TO DISTRIBUTOR COMPONENTS 1. Distributor cap 2. Rotorarm 3. Contact breakcr assembly 4. Capacitor and retaining screw 5. Dwell-angle adjuster screw and spring 6. Vacuum unit and retaining screws 7. Vacuum unit joint washer 8. Centrifugal advance cover plate and retaining scrcws 12. Thrust washer 13. Contact breaker L.T. lead and grommet 14. Distributor cam 15. Distributor drive dog .I 10. vacuum unit actuating iever ST1133M 3
86 OVERHAUL DUCELLIER DISTRIBUTOR - four cylinder engine DISMANTLE distributor. 16. Examine the advance mechanism of the cam, check e the shaft for excessive side play. If any of these parts arc damaged or worn renew the complcte ELECTRICAL EQUIPMENT - FOUR CYLINDER DISTRIBUTOR 1. Remove the distributor from the engine. 2. Remove the distributor cap. 3. Remove the rotor arm. 4. Remove the dust cover. 5. Remove the felt pad from the top of the rotor. 6. Remove the two screws retaining the condenser and vacuum unit and remove the condenser lead from the connector block. post. 7. Remove the retaining clip from the eccentric ‘D’ 8. Mark the position of the serrated cam in relation to the spring seat of the vacuum operating link. v ST1279M 9. Disengage the vacuum operating link and serratcd cam from the eccentric ‘D’ post and remove the vacuum unit. 10. Remove the retaining screw and withdraw the fixed contact plate. 11. Remove the retaining clip and insulation washer. 12. Release the connector block from the distributor body. 13. Lift out the moving contact complete with connector block and leads. 14. Mark the relationship of the base plate to the body and remove the retaining screw. Whilst holding the pressure pad clear of the rotor, withdraw the base plate. 15. Remove the moving contact post-plate. INSPECTION NOTE: The distributor drive dog is loosely retained on the drive shaft, the ‘float’ allows for any misalignment. 17. Examine all other components for damage or excessive wear and renew where necessary. 18. Check the distributor cover for signs of tracking or cracks and check that the pick-up brush moves freely in its holder. 19. Check the rotor arm for damage, electrode security, burning and tracking. continued 4
ELECTRICAL EQUTPMENT- FOUR CYLINDER DTSTRIBUTOR 186 I REASSEMBLE OVERHAUL LUCAS 45D4 DISTRIBUTOR - Four cylinder engine 20. Using Rctinax ‘A’ or equivalent grease lubricate the centrifugal weight pivot posts and lightly smear the cam pressure pad and contact pivot post. 21. Fit the pressure pad and spring to the base plate. 22. Fit the base plate to the body, lining up the marks, and secure with the retaining screw and clip on the opposite side to the vacuum unit. 23. Smear a little grease on the post and fit the moving contact post -plate to the base plate. 24. Offer up the vacuum unit to the body and fit the 25 I 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. operating link and serrated cam to the ‘D’ post. Ensure that the identification marks line up -see instruction 8. Secure the assembly with the spring clip. Secure the vacuum unit and condenser to the body with the remaining screw and clip. Fit the fixed contact and loosely retain with the screw. Fit the moving contact ensuring that the leaf spring locates in the nylon guide. Fit the connector block to the body. Fit the insulation washer and retain assembly with the spring clip. Fit condenser lead to connector block. Place the felt pad in the top of the rotor and add a few drops of oil. Smear a small quantity of grease on the rotor cam. Adjust the contact point gap to a datum setting of 0,43 mm (0.017 in) with a feeler gauge by turning the rotor spindle until a cam fully opens the points. Move the fixed contact plate to obtain the required gap and tighten the retaining screw. Fit the distributor to the engine. Fit the dust cover. Fit the rotor arm and distributor cap. Connect the H.T. leads to the appropriate spark plugs. Dismantling I. Remove the rotor arm. 2. Extract the felt pad, if fitted, from the cam. 3. Removc the two vacuum unit retaining screws, tilt .the unit to disengage the operating arm and remove the vacuum unit. 4. Push the low tension lead and grommet into the inside of the body. 5. Remove the securing screws and lift out the base plate assembly. 6. Drive out the parallel pin retaining the drive dog. 7. Remove the drive dog and thrust washer. 8. Remove the shaft complete with automatic advance mechanism and steel washer. 9. Push the moving contact spring inwards and detach the low tension connector from the spring loop. 10. Removc the screw to release the earth lead and capacitor. 11. Remove the sccuring screw and lift off the contact set. Inspection 12. Do not dismantle the advance mechanism beyond removing the control springs. If any of the moving parts or the cam are worn or damagcd, renew the complete shaft assembly. 13. Check the fit of the shaft in its bearing: if the bcaring allows cxcessive side play, renew the completc distributor. 14. Check the base plate assembly; if the spring between the plates is damaged or if the plates do not move freely, renew the assembly. 15. Check the distributor cap for signs of tracking or cracks and check that the pick-up brush moves freely in its holder. 16. Chcck the rotor arm for damage, electrode security, and burning or tracking. Keassem bling 17. Reverse the procedure in 1 to 11, noting thc following instructions. 18. Lubricate the contact pivot post with Retinax ‘A’ or equivalent grease. 19. Ensure that the steel washer is fitted on the shaft and lubricate the shaft with Rocol MP (Molypad). 20. Fit the thrust washer with its raised pips towards the drive dog. continued 5
14 ELECTRICAL EQUIPMENT - FOUR CYLINDER DISTRIBUTOR ST1832M 21. Fit the drive dog so that the driving tongues are parallel with the rotor arm electrode and to the left of its centre line when the rotor arm points upwards as shown. ST 22. If a new shaft is fitted it must be drilled through the hole in the drive dog using a 4.76 mm (A) drill. 23. During drilling, push the shaft from the cam end, pressing the drive dog and washer against the body shank. 24. Secure the pin in the drive dog by ring-punching the holes. If the shaft is new, tap the drive end to flatten the washer pips and ensure the correct end -float. 25. Set the contact points gap. g- ? 21 6
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