Land Rover Defender Workshop 1993 Rover Manual

							ELECTRICAL EQUIPMENT 
ELECTRONIC IGNITION - PRELIMINARY  CHECKS EXPECTED READINGS 
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  are  correctly 
positioned  and  not shorting 
to earth  against  any 
engine  components.  The  wiring  harness  and 
individual  cables  should  be  firmly  fastened  to prevent 
chafing. 
V1. More  than 11.5 volts 
V2. 1 volt max  below volts  at point 1 in test  circuit 
V3. 1 volt max  below  volts  at point 1 in test  circuit 
V4. 
0 volt 0.1 volt 
PICK
-UP AIR GAP 
Check  air  gap  with a  non
-ferrous feeler gauge. 
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 
1: 
Check  HT  Sparking 
Remove  coil/distributor 
HT lead from  distributor cover 
and  hold  approximately 
6 mm 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. 
(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. 
(e)  If coil  or amplifier 
is suspected,  disconnect LT 
lead at coil,  repeat  V3. If voltage is still 
incorrect, fit  new coil. 
If voltage  is now  correct, 
check 
LT lead, if satisfactory fit new  amplifier. 
(f) If engine  will not start  proceed  to  Test 3. 
KEY 
OK  Expected  Voltage. 
H  Voltage  higher than  expected. 
L  Voltage lower  than expected. 
TEST 
3: 
Check  Amplifier  Switching 
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. 
TEST 2: 
L.T. Voltage 
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. 
(b)  Compare  voltages  obtained  with  the  specified 
values  listed below: 
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If there is no  increase  in voltage  during cranking 
proceed 
to Test  4.  TEST 
5: 
Coil HT 
Sparking 
Remove  existing coil/distributor  HT lead  and 
fit test 
HT  lead 
to coil  tower.  Using suitable  insulated  pliers, 
hold  free end about 
6 mm  from  the engine  block and 
crank  the engine.  There should  be 
a good HT spark. 
If  weak  or no  sparking, 
fit new  coil,  repeat  test. 
HT  sparking  good, repeat  test with  original  HT lead. 
If  sparking  is good,  carry out Test 
6. 
If weak  or no  sparking, fit new  HT lead,  if engine will 
not  start  carry  out Test 6 
TEST 
4: 
Pick-Up Coil Resistance. 
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. If the  ohmmeter 
reading  is correct,  check all connections  between 
pick
-up  and  amplifier, if satisfactory,  fit new  amplifier. 
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. 
TEST 6: 
Rotor Arm 
Remove  distributor  cover. Disconnect  coil HT lead 
from  cover  and using  insulated  pliers, hold about 
3 
mm 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. 
If HT  sparking  occurs, an earth  fault on the  rotor  arm 
is  indicated.  Fit new  rotor  arm. 
If  engine  will not start  carry  out Test 
7. 
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TEST 7: 
Visual and HT Cable  Checks 
Examine:  Should be: 
1. Distributor  Cover  Clean, dry, no tracking 
2. Coil  Top  Clean, dry, no tracking 
3. HT  Cable  Insulation Must not be cracked 
4. HT  Cable  Continuity  Must not be open 
5. Sparking  Plugs  Clean, dry, and set to 
marks 
marks 
chafed 
or perished 
circuit 
correct  gap. 
NOTE: 
1. Reluctor  Must not foul  pick-up 
2. Rotor  and Flash Must not be cracked 
or 
leads 
or 
show signs of 
tracking  marks. 
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ALTERNATOR - TYPE A127  BATTERY 
Remove  and  refit 
Removal  WARNING: During battery removal  or  before 
carrying  out  any repairs  or  maintenance  to 
1. Disconnect battery ground  lead.  electrical  components  always disconnect  the 
2. Disconnect  the electrical  leads from the  battery  negative  lead  first. If the  positive lead is 
alternator.  disconnected with the negative  lead in place, 
3. Slacken  the two  tensioner  nuts and rotate  the  accidental  contact of the  wrench  to any 
tensioner  screw anti
-clockwise 
to slacken  the grounded 
metal part could  cause a  severe  spark, 
belt  tension.  possibly resulting  in personal  injury.  Upon 
4. Remove the belt.  installation of the battery  the  positive  lead 
5. Remove the two  securing  bolts and withdraw 
the  alternator  from the engine.  Remove  and 
refit 
should be connected  first. 
Removing 
1. Disconnect  battery ground  lead followed  by 
2.  Release  the four  nuts  securing  the battery 
3. Remove  the bracket  from the studs. 
4.  Remove  the battery 
the 
disconnection  of the  positive  lead. 
bracket  in position. 
Refitting 
5. Reverse  the removal  procedure. 
Refit  NOTE: Coat the  battery  clamps 
and 
terminals  with petroleum  jelly  before 
refitting. 
6. Position n 
the  alternator  on the engine and fit 
7. 
Adjust  the drive  belt tension,  see 
8. Connect the electrical  leads to the alternator 
the 
securing  bolts. 
MAINTENANCE. 
and  connect  the battery. 
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STARTER MOTOR - Type M78R 
Overhaul 
Dismantling 
1. Remove the  starter  motor.  13.  Withdraw the brushes  and bus bar. 
2.  Remove  the braid  between the  starter and the 
solenoid terminal. 
15. Remove  the yoke. 
3.  Remove  the solenoid  fixing  screws.  16. Remove  the  intermediate bracket. 
4. Withdraw  the solenoid  body.  17.  Loosen and remove  the  through bolts  from the 
5. Lift and  remove  the solenoid  plunger.  drive end bracket. 
6. Remove two nuts and two screws  from  the 
commutator  end  bracket. 
7. Remove the commutator  end  bracket. 
8.  Remove  the grommet  from  the  yoke. 
9. Lift the  brushbox  assembly  clear of the  jump ring back  towards  the drive. 
armature. 
21. Prise  the jump  ring from its  locating  groove. 
14. 
Remove  the armature  from the  yoke. 
18.  Remove the  sun  and  planet  gears. 
19.  Push  out  the  drive shaft sprocket  assembly 
from  the  drive  end  bracket. 
20. Carefully  tap  the  thrust  collar from over the 
10.  Remove the brush  springs. 22. Remove  the  drive  assembly  from  the  drive 
11.  Unclip  and remove  the earth brushes.  shaft. 
12. Remove the  insulating plate. 
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Inspecting 
Solenoid 
Solenoid  plunger removed, ohmmeter  should read 
infinity. 
23.  Check  the  continuity  and resistance  value 
of 
windings  by connecting  an  ohmmeter  as 
shown. 
Solenoid plunger operated by  hand, ohmmeter 
should  read zero. 
If test results  are unsatisfactory,  replace  the 
solenoid. 
If results  are correct  proceed  to 25. 
(a) Resistance  value  should  be: 1.074  ± 0.035 
ohms  25.  Check operation 
of spring for freedom of 
movement. 
Brush gear 
26. Check  brush springs  and  ensure  that the 
brushes move  freely in their  holders. 
Clean  the brushes  with a petrol  moistened  cloth, if 
required. 
(b)  Resistance  value  should  be: 
0.298 ± 0.015 
ohms 
If test results  are  unsatisfactory  replace the solenoid. 
If results are  correct proceed to 24. 
24.  Check  the  contacts by connecting  an 
ohmmeter  as  shown. 
Brush length new, Dimension 
A is 9 mm. 
Minimum  brush length,  Dimension  B is  3.5 
mm. 
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NOTE: Soak new bushes  in engine oil for  thirty 
minutes  before fitting. 
Reassembly 
Armature 
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  34. Reverse  the instructions  1 to  22.  Smear  the 
test  lamp. 
If the lamp  illuminates  the armature  teeth and operating  collar of the  roller  clutch 
is faulty,  and a replacement  component IS with Shell  Retinax A grease.  Smear the pivot 
required.  lever 
of the  drive  assembly  with Mobil 
22 
grease.  Smear the drive  shaft sun and  planet 
gears  with 
Rocol ERE1200 grease. 
35.  Tighten  all the  fixings 
to the  correct  torque - 
see Torque  Wrench  Settings, SECTION 06 . 
HEADLAMPS 
To  remove  or renew  bulb or light  unit 
1. Remove  the two screws and withdraw  the 
2.  Remove  the 
two screws and withdraw  the 
front  flasher  lens. 
3.  Remove  the three  screws  retaining  the side 
lamp 
to the  wing. 
4. Remove  the three  screws  securing  the flasher 
lamp. 
5. Ease  the side  and flasher  lamps from their 
28. 
If necessary,  the commutator  may be  locations in the  wing  and pull them  out as far 
as  the  leads  will allow. 
6. Remove  the screws  retaining  the plastic  bezel 
to the wing. 
7. Withdraw  the bezel  sufficiently  to gain  access 
to the headlamp  retaining screws. 
front 
side lamp  lens. 
machined,  providing a finished  surface can be 
obtained  without reducing  the diameter  below 
28.8 
mm 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  rotate 
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  end/intermediate  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. 
33.  Commutator  end bracket:  thread a 9/16 
Whitworth  or suitable  similar tap firmly  into the 
bush.  Extract  the bush  with the tap using  a 
power  press in reverse. 
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11 Discard  the light unit,  or release  the spring 
8. Remove  the  three  screws  retaining  the rim  clip  and discard  the  bulb if faulty. 
and  light  unit,  and remove  the rim. 
12. If required,  fit  a new bulb of the  correct 
9. Withdraw  the  light  unit or reflector  and  wattage and secure  with  the  spring clip, or fit 
disconnect  the  electrical connector.  a 
new  light  unit. 
10 Remove the rubber  grommet. 
14. Disconnect the  electrical  leads  from the bullet 
connectors  and remove the  headlamp shell. 
15.  Remove the rubber  seal. 
To remove  or renew  headlamp  assembly 
13. Remove  the  four screws  and  release the 16. Release  the  two trimmer  screws  and  coil 
spring  and detach  the  rim seating  from  the 
headlamp shell. 
headlamp 
shell from the  front  wing. 
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							ELECTRICAL EQUIPMENT 
Assemble and refit 27. The  beam  centres  A are  measured 
horizontally  on the  vehicle  and the dimension 
B  vertically  from the ground. 
17. Fit the  rim seating  to the  headlamp  shell with 
the  two  trimmer  screws and coil spring. 
18.  Fit the  rubber  seal to the  headlamp  shell. 
19.  Connect  the leads  to the  bullet  connectors. 
20.  Fit the  headlamp  shell into the front  wing 
locating  the trimmer  screws into the 
two holes 
in the  wing.  Ensure  that the assembly  is 
located,  as illustrated,  with one trimmer  screw 
at  the  12 oclock  position  and the other  90° to 
the  left. 
21.  Secure  the shell  assembly  to the  wing  with 
the  four  screws. 
22.  Offer
-up the  light  or reflector  unit to the  rim 
seating  and connect  the electrical  connector. 
23.  Secure  the assembly  with the rim and  three 
screws. 
24.  Refitting 
of the plastic  bezel and lamps is a 
reversal  of instructions  1 to  7. Ensure, 
however,  that when  fitting  the side  and flasher 
lamps  the gap  in the  seal  surround  is located 
at  the  bottom 
to provide  for drainage  and 
ventilation. 
25. Remember  to replace  or renew  the rubber 
sealing  washers  over the screws  inside each 
lens.  Also check  that the fibre  washers  are in 
place  under  the screw  heads  on the  outside 
of 
the  lens. 
25. Check  the main  beam  setting  using beam 
setting  equipment.  Should this not be 
available  the beam  can be temporarily 
checked  and adjusted  in the  following  way:
- 
26. Position the vehicle  on level  ground  with the 
tyres  correctly  inflated, approximately  four 
meters  from a wall  or screen,  marked  as 
illustrated. 
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SIDE, TAIL AND FLASHER  LAMPS 
Renew  bulbs and lamps  REAR NUMBER PLATE  LAMP 
Remove  and renew  bulbs 
1. Disconnect the  battery. 1. Disconnect the  battery  and remove  the  single 
2.  Remove  the two  screws  and  fibre washers 
and  withdraw  the  lens  and  collect  the 
two 
rubber  washers inside the  lens. 3. Disconnect the electrical  leads. 
screw 
securing the  lamp  cover and lens. 
2. At this stage  the bulbs  only can be renewed. 
3. Push  the bulb  inwards,  twist  and  withdraw. 4. Remove the  cover  from  inside  the vehicle 
4. Remove  the three  screws  and withdraw  the  body. 
lamp  holder  complete.  Disconnect  the 
5. Remove  the  two  nuts and washers  securing 
electrical  leads  from the  bullet  connectors  the  lamp to  the vehicle  body. 
inside the  vehicle  wing for the  front  lamps. 
For 6. Remove  the  bulb  holder complete  with  rubber 
rear  lamps  remove  the  cover  inside the body  seal  and  mounting block. 
for  access  to  the connectors. 
5. If necessary  remove the  rubber  bulb  holder 
cover. 
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 bottom. 
8. Connect  the electrical  leads  to  the bullet 7. Assemble  the  bulb holder  and rubber  seal  to 
connectors. 
9. Fit  the  lamp  to  the  vehicle,  observing  the  mounting  block,  connect  the leads  and fit 
to the  vehicle  body  with  the two  screws  and 
instruction 7, and  secure  with the three 
nuts. 
screws. 
10. Fit the  bulb of the same wattage,  if renewed.  8. Fit the  bulbs. 
9. Fit  the  lens and lamp  cover  and secure  with 11. Fit the  lens  ensuring  that the  rubber  and  fibre 
washers  are  correctly  positioned.  Evenly  the single  screw.  Connect  the battery  and  test 
tighten  the 
two screws.  Overtightening  could  the  lamp. 
crack  the lens. 
Refitting  lamp and bulbs 
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