Land Rover Defender 90 110 Workshop 1984 Rover Manual

							ELECTRICAL EQUIPMENT 
STARTER MOTOR - Paris Rhone - 4 cylinder  Diesel 
Dismantle  and 
Test 
, I.. .* r. -> ‘. 5.r 
t 
86 
DISMANTLE 
1. Remove  starter motor from engine. 
2. Disconnect  field winding  lead from  the solenoid. 
3.  Remove  the two  nuts  and withdraw 
the solenoid, 
plungcr and spring. 
4.  Removc  the terminal  strap. 
5. Remove the two through-stud nuts. 
6. Remove  the brush  plate cover. 
7. Withdraw  the yoke  complete  with brush  plate 
assembly  whilst noting 
the position of the yoke 
location  plate 
in the reduction  gear housing. 
8. Remove  the single  socket  headed  screw and 
withdraw  the armature  and reduction  gear housing 
from 
the drive-end  bracket. 
9.  Remove 
the clutch  drive and pinion  assembly. 
* . 10. Withdraw  the brushes  from the holders. 
Inspection  and test 
11. Examinc all parts  for condition.  Check the 
bearings  and bushes  and pinion  drive assembly  for 
wear.  Examine  the reduction 
drivc pinion  and 
drive 
gcar intcrnal tecth. Check  the field  coil and 
armature  brushes. 
Armature 
12. Using  very fine glass  paper,  clean the commutator 
and  wipe  the surface  with a petrol
-moistened  cloth. 
Do not undercut  the insulation slots. 
13.  Check  the armature  insulation  by connecting  a 110 
V.A.C. 15 W test lamp betwecn each  commutator 
segment 
in turn  and thc armaturc  shaft. The lamp 
should 
not light. 
ST1846M 
.. .. ., .. . ,;: !.’ , . .. . .. 
Field  coil insulation 
14. Connect a 110 V.A.C. 15 W test  lamp  between  the 
disconnected  end of the  winding  and 
a clean part of 
the yoke, 
15. Ensure  that the brushes or leads  do not  touch  the 
yoke  during  the 
test. 
16. The lamp should  not light; if it does  light, fit a ncw 
field coil assembly. 
. 
ST1847M 
Field coil continuity 
17.  Connect a 12 V battery-opcrated  test lamp 
18. The lamp should  light; if it does not light, fit a new 
between  each brush  in turn  and a link lead. 
field  coil assembly. 
STl848M 
Solenoid 
19.  Disconnect all cables from the solcnoid tcrminals 
and  connectors. 
20.  Connect  a 12 
V battcry  and a 12 V 60 W test  lamp 
across  the 
solcnoid main terminals.  The lamp 
should  not light;  if it  does  light, 
fit a new  solenoid 
complete. 
21.  Leave  the test  lamp  connected  and, using  the same 
12 V battery  supply,  energize  the solenoid  by 
connecting 
a 12 V supply  between  the small 
solenoid operating  Lucar terminal  blade and a 
good earth  point on the solenoid  body. 
continued 
41  
						

							Battery connection 
Earth  connection 
Socket  headed  screw 
Field  winding  to solenoid  nut 
Through
-stud  nut 
Brush  cover nuts 
Solenoid  retaining  nuts 
11 NM 
11 NM 
7-C 1,4NM 
9,5 -C 1,5 NM 
8,5 k 1,5 NM 
4,2 
_+ 0,6 NM 
3,l -C 0,4NM 
I86 I ELECTRICAL EQUIPMENT 
i 
29. Fit the through-studs  to the  drive-end  bracket. 
30. 
Fit the  brush  plate cover  and secure to the brush 
31. 
Sccure the  assembly  with the through-stud  nuts. 
32. 
Fit the terminal  strap to the through-studs  and 
retain  with the two  nuts. 
33. 
Fit the  coil  spring  to the  solenoid  plunger and 
assemble  the solenoid 
to the  drive-end  bracket  and 
secure  with the two  nuts. 
34.  Check  that the starter  motor turns freely  without 
tight  spots. 
plate 
with the two  nuts. 
U -- ST1853M 
22. The  solenoid  should be heard  to operate  and the 
test  lamp  should  light with full brilliance,  otherwise 
fit a new  solenoid  complete. 
TIGHTENING TORQUES 
ASSEMBLE 
23. Fit the  round  rubber  pad to the  drive-end  bracket. 
24.  Fit the  lever 
to clutch  drive and pinion  assembly 
and  fit to the  drive
-end  bracket  ensuring  that the 
two washers  are in position on the  shaft. 
25.  Check  that the fibre  washer  is positioned 
on the 
shaft  inside  the reduction  gear. 
ST1849M 
26. Place  the rubber  pad, with plain  side towards  the 
drive
-end  bracket fit the ‘0’ ring  seal and assemble 
and  secure  with the single  socket
-headed  bolt. 
27.  Place  the yoke  location  plate in position 
in the  slot 
in  the  reduction  gear housing  and fit the  yoke  and 
brush  plate to 
the armature. 
28, Insert  the brushes  into their  holders and release  the 
retaining  springs. Ensure that 
the brushes  rest 
correctly  on 
the commutator. 
the :educ!ie:: gear heusing tG the d:ive=end bracket 
42  
						

							ELECTRICAL EQUIPMENT (861 
- . . .. .. . .. . .. , 
ST1833M 
1. Solenoid 
2. Solenoid  plunger and spring 
3. Drive-end  bracket  and bush 
4. Reduction  gear pinion 
5. Reduction  gear 
6. Rubberpad 
7. 0 ring seal 
8. Lever 
9. Clutch  drive and pinion  assembly 
10. Rubber  pad 
11.  Armature 
KEY TO STARTER MOTOR 
12. Yoke 
13. Roller  bearing 
14. Through-studs 
15. Brush plate 
16. Field coil brushes 
17. Armature  brushes 
18. Brush plate cover 
19. Reduction  gear housing 
20. Socket-hcaded  screw 
21.  Terminal  strap 
22.  Yoke  location  key 
, .. . I ,: .,. . - .. . I.. . 
43  
						

							186/ ELECTRICAL EQUIPMENT 
STARTER MOTOR - Paris Rhone,  Turbo  charged 2.5 
Diesel engine. 
Removing 
1. Disconnect  the battery. 
2. Slacken  the four  nuts  securing the intermediate 
exhaust  pipe  heat  shield 
and move the shield 
rearwards. 
3. Remove  the exhaust  flange nuts and bolts. 
ST1859M  // 
4. Remove  the bolt  securing  the front  downpipe to 
the cylinder  block. 
5. Release  the clamp  securing  the front  downpipe  to 
the  turbo
-charger  elbow. 
6. Remove  the front  downpipe. 
7. Disconnect  the earth  straps  from the starter  motor. 
8. Disconnect  the battery,  alternator  and ignition 
leads  from the starter  motor. 
9. Remove  the starter  motor fixings  to the  engine  i.e. 
one nut and  bolt,  one nut and  one  bolt. 
10. Remove  the startcr motor. 
Fitting 
11. Fit starter motor to engine  locating it on the single 
stud  and secure  with the remaining  fixings and 
evenly  tighten  to the  correct torque. 
12. Conncct  the alternator,  ignition and battery  leads 
to  the  starter  solenoid. 
13. Connect  the earth  leads to the rear of the  starter 
motor. 
14. Fit the  exhaust  front-pipe to the intermediate 
system  and evenly  tighten  the  three  bolts. Re
- 
position  the heatshield  and tighten the four  nuts. 
15. Connect  the front  pipe to the turbo-charger  elbow 
and  secure  with the clamp. 
16. Secure  the front pipe to the cylinder  block with the 
single  bolt. 
44  
						

							ELECTRICAL 
45 
m 
86  
						

							I86 I ELECTRICAL 
Inspecting 
Solenoid 
23. Check  the continuity  and resistance  value of 
windings by connccting an ohmmeter  as shown. 
RR1812E 
(a)  Resistance  value should  be: 
1.074 
k 0.035  ohms 
(b) 
RR18l3E 
(b) Resistance  value should  be: 
0.298 k 0.015 ohms 
If  test  results  are unsatisfactory  replace the solenoid. 
If results  arc correct  proceed to 24. 
24. 
Check the  contacts by connecting  an ohmmeter  as 
shown. 
Solenoid  plunger removed,  ohmmeter  should read 
infinity. 
RRl814E 
Solenoid  plunger operated  by hand,  ohmmeter 
should  read zero. 
If test  results  are unsatisfactory,  replace the g-x 
If results  are correct  proceed  to 25. 
movement. solenoid. 
g.2 
25. 
Check  operation  of spring  for freedom of 
Brush gear 
26. Check  brush springs  and ensurc that the brushes 
move  freely  in their  holders. 
Clean  the brushcs  with a petrol 
moistencd cloth, if 
requircd. 
RR1815E 
Brush length  new, Dimension A is 9 mm 
(0.354 in). 
Minimum  brush length,  Dimension 
B is 3.5 mm 
(0.138  in). 
46  
						

							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