Land Rover Defender 90 110 Workshop 1984 Rover Manual
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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
4 .. :. . . .. .. . .. .. ... ... . . . . . . ., .. ,. . : .,, ..... .. . ..I .. , .- .. - lest ault Check Rectification ;NITION SYSTEM Connect 0 - 1 V voltmeter as in Test 15c. fit a jumper lead from earth to distributor body, with ignition on and contact breaker points closed: (i) Below 0.2V Remake earth connections between distributor body and earth (ii) Above 0.2V- High resistance or open circuit in distributor Checklrepair or renew contact breaker points, base plate screws earth lead or supply lead as necessary Connect 0 - 20 V voltmeter as in Test 15b, with ignition on and contact breaker points open: (i) Above 12 V- Continuity in primary windings of coil, supply line and ballast resistor if fitted Carry out Test 15g Carry out Test 15f ~ ~~~~ ~ (ii) Zero-open circuit feed to coil, open circuit primary windings, open circuit (iii) ballast resistor if fitted or short circuit in distributor or coil negative lead Connect 0 - 20 V voltage as in Test 15b, with ignition on and contact breaker points open. Remove coil negative lead from coil and recheck voltage: (i) Above 12V-Short circuit in coil, negative lead or distributor Check contact breaker points correctly fitted, short circuit in condenser (or capacitor when ballast resistor fitted) or SUPDIV lead; reDair or renew Carry out Test 15~ (ii) Zero -reconnect coil negative lead Connect 0 - 20 V voltmeter between earth and coil positive terminal, with ignition on and contact breaker points closed: (i) Above 12V -Coil primary windings open circuit (ii) 11.5V - 12V without ballast resistor If result of Test 15f was above 12V L.T. circuit is satisfactory 5V - 7V with ballast resistor (iii) Below 1l.W or zero without ballast resistor - Excessive resistance or open circuit supply to coil. Leaving the voltmeter connected to earth, work back through the supply circuit at the terminals on the ignition switch and solenoid until the resistance or open circuit is located Renew coil Fault elsewhere Rectifv and recheck (iv) Below 5V or zero with ballast resistor- Excessive resistance or open circuit in supply to coil Carry out Test 15H Connect 0 - 20 V voltmeter between earth and the lead from the ballast resistor to the coil positive terminal, with the ignition on and contact breaker points closed: (i) 5V - 7V or above 12V - Fault in the ballast resistor to coil lead Repair or renew lead then re-test ~~ ~ Carry out Test 15j (ii) Below 5V or zero -Excessive resistance or open circuit between battery and coil Connect 0 - 20 V voltmeter between earth feed lead to ballast resistor, with ignition on and contact breaker points closed: (i) Above 12V -Fault in ballast resistor Renew and re-test. If satisfactory fault elsewhere (ii) Zero or below I1.W- Fault in supply circuit from battery. Leaving the voltmeter connected to earth, work back through the supply circuit at the terminals on the ignition switch and solenoid until the fault is located. Rectify and re-test. If satisfactory fault elsewhcrc continued
ault Check GNITION SYSTEM rEST EQUIPMENT :A) Voltmeter 0 - 20V moviing coil :B) Voltmeter 0 - 1V movin;g coil Dhmmeter Test 14. H.T. Circuit kl ST1307M H ST1308M Disconnect main H.T. lead from distributor cap, hold approximately 6 mm (V4 in) from a good earth, ensure contact breaker points are closed, switch on ignition and flick contact breaker points open. Good healthy spark-Main H.T. lead, condenser and coil satisfactorv Poor or no soark Replace main H.T. lead with a known good H.T. lead and repeat Test Good healthy spark - Original H.T. lead faulty Poor or no soark Replace condenser with a known good one and repeat Test Good healthy spark - Original condenser faulty Poor or no soark Replace ignition coil with a known good coil and repeat Test Good healthy spark - original coil faulty e. Hold loose end of main H.T. lead approximately 3 mm (/I in) from the rotor arm electrode. Ensure contact breaker points are closed, switch on ignition and flick points open (i) Good healthy spark - Rotor arm shorting to earth (ii) Very faint or no spark - Rotor arm insulation satisfactory Check battery voltage and state of charge Connect voltmeter 0 - 1V between earth and coil negative terminal with ignition on and contact breaker points closed: (i) Below0.2V (ii) Above 0.2V- Resistance or open circuit Connect 0 - 1V voltmeter bttween earth and distributor L.T. terminal with ignition on and contact breaker points closed: (i) 15. L,.T. circuit continuity check: a. b. c. Below 0.2V -Resistance or open circuit between coil negative and distributor L.T. terminal (ii) Above 0.2V - Resistance or open circuit between earth and distributor L.T terminal Rectification Carry out Test 14e Carry out Test 14b Renew main H.T. lead. Carry out Test 14e Carry out Test 14c Renew condenser. Carry out Test 14e Carry out Test 14d Renew coil, refit original H.T. lead and condenser and repeat Tests 14a and b, or carry out Test 14e Renew rotor arm Carry out Test 15 See STARTING SYSTEM Carry out Test 15e Carrv out Test I5c Renew lead Carry out Test 15d continued
U U Connect voltmeter (B) as in Test 15C, fit ajumper lead from earth to distributor body, with ignition on and contact breaker points closed: (i) Below 0.2V (ii) Above 0.2V- High resistance or open circuit in distributor Connect voltmeter (A) as in Test 15b, with ignition on and contact breaker points open: (i) Above 12 V- Continuity in primary windings of coil, supply line and ballast resistor if fitted (ii) Zero -open circuit feed to coil, open circuit primary windings, open circuit ballast resistor if fitted or short circuit in distributor or coil -ve lead Connect voltage (A) as in Test lSb, with ignition on and contact breaker points open. Remove coil -ve lead from coil and recheck voltage: (i) Above 12 V- Short circuit in coil, -ve lead or distributor (ii) Zero -reconnect coil -ve lead Connect voltmeter (A) between earth and coil +ve terminal, with ignition on and contact breaker points closed: (i) Above 12V -Coil primary windings open circuit auk Checl Remake earth connections between distributor body and earth Checkhepair or renew contact breaker points, base plate screws earth lead or supply lead as necessary Carry out Test 15g Carry out Test 15f Check contact breaker points correctly fitted, short circuit in condenser (or capacitor when ballast resistor fitted) or supply lead; repair or renew Carry out Test 15g Renew coil ;NITION SYSTEM ,ontinued) (ii) 11SV - 12V without ballast resistor If result of Test 15f was above 12V L.T. circuit is satisfactory 5V - 7V with ballast resistor - est I Rectification Fault elsewhere (iii) Below 11.W or zero without ballast resistor - Excessive resistance or open circuit supply to coil. Leaving the voltmeter connected to earth, work back through the supply circuit at the terminals on the ignition switch and solenoid until the resistance or open circuit is located (iv) Below 5V or zero with ballast resistor-Excessive resistance or open circuit in supply to coil Connect voltmeter (A) between earth and the lead from the ballast resistor to the coil +ve terminal, with the ignition on and contact breaker points closed: (i) 5V - 7V or above 12V- Fault in the ballast resistor to coil lead (6) Below SV or zero-Excessive resistance or open circuit between battery and coil Connect voltmeter (A) between earth feed lead to ballast resistor, with ignition on and contact breaker points closed: (i) Above 12V -Fault in ballast resistor Rectify and recheck Carry out Test 15h Repair or renew lead then re-test Carry out Test 15j Renew and re-test. If satisfactory fault elsewhere (ii) Zero or below 11.W- Fault in supply circuit from battery. Leaving the voltmetei connected to earth, work back through the supply circuit at the terminals on the ignition switch and solenoid until the fault is located. Rectify and re-test. If satisfactory fault elsewhere I continued
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