Land Rover 90 110 Workshop Rover Manual
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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
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