Content .. 143 144 145 146 ..

Defender 90 / 110 / 130. Manual - part 145

ELE

RICAL E

PMENT

STARTER MOTOR

Paris Rhone

cylinder Diesel

Dismantle and Test

DISMANTLE

1. Remove starter motor from engine.

2. Disconnect field winding lead from the solenoid.
3. Remove the two nuts and withdraw the solenoid,

and spring.

4. Removc the terminal strap.

Remove the

two through-stud nuts.

6. Remove the brush plate cover.
7.

Withdraw the yoke complete with brush plate

assembly whilst noting

position of the yoke

location plate i n 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

clutch drive and pinion assembly.

Withdraw the brushes from the holders.

Inspection and test

11.

all

parts for condition. Check the

bearings and bushes and pinion drive assembly for
wear. Examine the reduction

pinion and

drive

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

V.A.C. 15

test lamp

each commutator

segment in turn and

armaturc shaft.

The lamp

should not light.

. .

Field coil insulation

14.

Connect a 110

V.A.C.

W test lamp between the

disconnected end of the winding and

clean part

the

yoke,

15. Ensure that the brushes or leads do not touch the

yoke during the

16.

The lamp should not light;

if it does light, fit a

field coil assembly.

Field

coil continuity

17. Connect a 12 V battery-opcrated test lamp

18.

lamp should light;

if i t

does not light, fit a

between each brush in turn and a link lead.

field coil assembly.

Solenoid
19. Disconnect

all cables from the solcnoid

and connectors.

20. Connect a 12

V battcry and a 12 V 60 W test lamp

across the

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

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

Battery connection
Earth connection
Socket headed screw
Field winding to solenoid nut
Through-stud nut
Brush cover nuts
Solenoid retaining nuts

11 NM

7-C

1,5 NM

4,2

0,6 NM

ELECTRICAL

EQUIPMENT

29. Fit the through-studs to the drive-end bracket.
30. Fit the brush plate cover and secure

the brush

31.

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.

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
two washers are in position

on the shaft.

25. Check that the fibre washer is positioned on the

shaft inside the reduction gear.

26. Place the rubber pad, with plain side towards the

drive-end bracket fit the

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

t h e armature.

Insert the brushes into their holders and release the
retaining springs. Ensure that the brushes rest

correctly on

t h e

commutator.

the

bracket

ELECTRICAL EQUIPMENT

1. Solenoid

2 . Solenoid plunger and spring
3. Drive-end bracket and bush

Reduction gear pinion

Reduction gear

Rubberpad

ring seal

Lever

9. Clutch drive and pinion assembly

10. Rubber pad
11. Armature

KEY

TO STARTER

MOTOR

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

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.

Remove the exhaust flange nuts and bolts.

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.

Remove the front downpipe.

7. Disconnect the earth straps from the starter motor.

Disconnect the battery, alternator and ignition
leads from the starter motor.

Remove the starter motor fixings to the engine i.e.

one nut and bolt, one nut and one bolt.

10. Remove the

motor.

Fitting

11.

Fit starter motor to engine locating

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

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 t h e four nuts.

15. Connect the front pipe to the turbo-charger elbow

and secure with the clamp.

16. Secure the front pipe

the cylinder block with the

single bolt.

Content .. 143 144 145 146 ..