Section Number

CONTENTS
HEATER

i=. "-?

'rF*

80
82

AIR CONDITIONING MAINTENANCE

82

COMPRESSOR
- R e m o v eand refit - Drive belt adjustment

17
1 0

82

CONDENSER
- Fan motors remove and refit - Condenserrcmove and refit -Receiver drier remove and refit

18 19
1O

82

EVAPORATOR
- R e m o v eand refit - L.H. Steering - Resistor block - remove and refit - Blowermotor - R . H . Steering, remove and refit 20 23

24

Section Number

CONTENTS
Page ELECTRICAL PRECAUTIONS - Polarity - Highvoltage circuits -Connectors and harncss - Batterydisconnections - Batterycharging - Generalprecautions - Testequipment

186I

86

ELECTRICAL E Q U I P M E N T
- OverhaulV8 engine distributor -Overhaul four cylinder engine distributor -Ducellier -Overhaul four cylinder cngine distributor - Lucas - Electronicignition distributor type 35DMS -V8 engine - Electronicignition distributor type 3 5 D L M 8 -V8 cngine - Overhaulalternator -all models - Lucas A l 15-34 and A l 15-45 - Overhaulalternator - all models -Lucas A127/65 -Alternator functional check - D i o d efault symptoms - A l t e r n a t o rfault and diagnosis chart - Overhauldiesel engine starter motor - OverhaulV8 engine starter motor - Overhaulfour cylinder petrol engine starter motor - Overhaul- Paris-Rhone 4 cylinder Diesel engine starter motor -Rcmovc and refit 2.5 Turbo chargcd Diesel engine starter motor - Overhaul Lucas M78R starter motor -Lamps -Overhaul wiper motor 2 4

5
7 13 20 24 28 29 29 30 34 37 41 44 45 48 52

k.;:

pL

E L E C T R I C A L E Q U I P M E N T -F A U L T T R A C I N G - Introduction - Chargingsystcm - Ignitionsystem - Startersystem 54 55 56 60

-.

_,"

IS6

CIRCUIT DIAGRAMS
- F o u rcylinder petrol engine - 2.25litre diesel engine - 2.5 litre diesel engine -V8 cylinder engine - Compositecircuit diagram - 1986 onwards all models -Dim-dip circuit diagram - TwinT a n k -Twin pumps - Optionalequipment circuit diagrams 64 66 68 70 72 74 75 76

II

. ... aI
I .

Special Service Tools

The use of approved special service tools is important. They are essential if servicc operations are to be carried out efficiently, and safely. The amount of time which they save can be considerable. Every special tool is designed with the close co-operation of Land Rover Ltd., and no tool is put into production which has not been tested and approved by us. New tools are only introduced where an operation cannot be satisfactorily carried out using existing tools or standard equipment. Thc user is therefore assured that the tool is necessary and that it will perform accurately, efficiently and safely. Special tools bulletins will be issued periodically giving details of new tools as they are introduced. A 1 orders and enquiries from the Unitcd Kingdom should be sent direct to V. L. 1 Churchill. Overseas orders should be placed with the local V. L. Churchill distributor, where one exists. Countries where there is n o distributor may order direct from V. L. 4NF. Churchill Limited, PO Box 3 Daventry, Northants, England "11 The tools recommended in this Workshop Manual are listed in a multi-language, illustraicd catalogue obtainable from Messers. V. L. Churchill at the above address under publication number 2217/2/84 or from Land Rovcr Ltd., under part number LSM0052TC from t h e following address, Land Rovcr Merchandising Scrvice, P.O. Box 534, Erdington, Birmingham B24 OQS.

INTRODUCTION

e!,

. .

This Workshop Manual covers the Land Rover Ninety and One Ten range of vehicles. It is primarily designed to assist skilled technicians in the efficient repair and maintenance of Land Rover vehicles.
Using the appropriate service tools and carrying out the procedures as detailed will enable the operations to be completed within the time stated in the Repair Operation Times. The Manual has been produced in separate books; this allows the information to be distributed throughout the specialist areas of the modern service facility. A table of contents in Book 1 lists the major components and systems together with the section and book numbers. The cover of each book details the sections contained within that book.

I,

The title page of each book carries the part numbers required to order replacement books, binders or complete Service Manuals. This can be done through the normal channels.

-.

REFERENCES References to the left- or right-hand side in t h e manual are made when viewing the vehicle from the rear. With the engine and gearbox assembly removed, the water pump end of the engine is referred to as the front. To reduce repetition, operations covered in this manual do not include reference to testing the vehicle after repair. It is essential that work is inspected and tested after completion and if necessary a road test of the vehicle is carried out particularly where safety related items are concerned.

DIMENSIONS The dimensions quoted are to design engineering specification. Alternative unit equivalents, shown in brackets following the dimensions, have been converted from the original specification. During the period of running-in from new, certain adjustments may vary from the specification figures given in this Manual. These adjustments will be re-set by the Distributor or Dealer at the After Sales Service, and thereafter should be maintained at t h e figures specified in the Manual.

REPAIRS AND REPLACEMENTS When replacement parts are required it is essential that only Land Rover parts are used. Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and accessories: Safety features embodied in the vehicle may be impaired if other than Land Rover parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the vehicle manufacturers specification. Torque wrench setting figures given in the Repair Operation Manual must be strictly adhered to. Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed. Owners purchasing accessories while travelling abroad should ensure that thc accessory and its fitted location on the vehicle conform to mandatory requirements existing in their country of origin. The terms of t h e Owners Service Statement may be invalidated by the fitting of other than Land Rover parts. All Land Rover parts have the full backing of the Owners Service Statement. Land Rover Distributors and Dealers are obliged to supply only Land Rover service parts.

POISONOUS SUBSTANCES Many liquids and other substances used in motor vehicles are poisonous and should under n o circumstances be consumed and should as far as possible be kept away from open wounds. These substances among others include antifreeze, brake fluid, fuel, windscreen washer additives, lubricants and various adhesives.

_. .

FUEL HANDLING PRECAUTIONS The following information providcs basic precautions which must be observed if petrol (gasoline) is to be handled safely. It also outlines the other areas of risk which must not be ignored. This information is issued for basic guidance only, and in any case of doubt appropriate enquiries should be made of your local Fire Officer.
iii

GENERAL Petrol/gasoline vapour is highly flammable and in confined spaces is also very explosive and toxic. When petrol/gasoline evaporates it produces 150 times its own volume in vapour, which when diluted with air becomes a readily ignitablc mixture. The vapour is heavier than air and will always fall to the lowest level. It can readily be distributed throughout a workshop by air current, consequently, even a small spillage of petrol/gasoline is potentially very dangerous. Always have a fire extinguisher containing FOAM CO2 GAS, or POWDER close at hand when handling or draining fuel, or when dismantling fuel systems and in areas where fuel containers are stored. Always disconnect the vehicle battery BEFORE carrying out dismantling or draining work on a fuel system. Whenever petrol/gasoline is being handled, drained or stored, or when fuel systcms are being dismantled all forms of ignition must be extinguished or removcd, any head-lamps used must be flameproof and kept clear of spillage.

NO ONE SHOULD BE PERMITTED T O REPAIR COMPONENTS ASSOCIATED WITH PETROL/ GASOLINE WITHOUT FIRST HAVING H A D SPECIALIST TRAINING.

FUEL TANK DRAINING

WARNING: PETROL/CASOLINE MUST NOT BE EXTRACTED OR DRAINED FROM ANY VEHICLE WHILST IT IS STANDING OVER A PIT. Draining or extracting petrol/gasoline from vehicle fuel tank must be carried out in a well ventilated area. The receptacle used to contain the petrol/gasoline must be more than adequate for the full amount of fuel to be extracted or drained. The receptacle should bc clearly marked with its contents, and placed in a safe storage arca which meets the requirements of local authority regulations. WHEN PETROL/GASOLINE HAS BEEN EXTRACTED O R DRAINED FROM A FUEL TANK T H E PRECAUTIONS GOVERNING NAKED LIGHTS A N D IGNITION SOURCES SHOULD BE MAINTAINED. FUEL TANK REMOVAL On vehicles where the fuel line is secured to the fuel tank outlet by a spring steel clip, it is recommended that such clips are released before the fuel line is disconnected o r the fuel tank unit is removed. This procedure will avoid the possibility of residual petrol fumes in the fuel tank being ignited when the clips are released. As an added precaution fuel tanks should have a PETROL/GASOLINE VAPOUR warning label attached to them as soon as they arc removed from the vehicle.

8.

-+--,

a ,

FUEL TANK REPAIR

Under n o circumstances should a repair to any tank involving heat treatment be carried out without first rendering the tank SAFE, by using one of the following mcthods: STEAMING: With the filler cap and tank unit removed, empty the tank. Steam the tank for at least two hours with low pressure steam. Position thc tank so that condensation can drain away frecly, ensuring that any sediment and sludge not volatised by the steam, is washed out during the steaming process. BOILING: With the filler cap and tank unit removed, empty the tank. Immerse the tank completely in boiling water containing an effective alkaline dcgreasing agent or a detergent, with the water filling and also surrounding thc tank for at least two hours. After steaming or boiling a signed and dated label to this effect should be attached to the tank.

SPECIFICATION
Purchasers are advised that the specification details set out in this Manual apply to a range of vehicles and not to any one. For the specification of a particular vehicle, purchasers should consult their Distributor or Dealer. The Manufacturers reserve the right to vary their specifications with or without notice, and at such times and in such manner as they think fit. Major as well as minor changcs may be involved in accordance with the Manufacturers policy of constant product improvement. Whilst every effort is made to ensure the accuracy of the particulars contained in this Manual, neither the Manufacturer nor the Distributor or Dealer, by whom this Manual is supplied, shall in any circumstances be held !iab!e fer any i n a c c u r x y or thc consequences thereof.

COPY RIGHT
@

Land Rover Limited 1984

All rights reserved. No part of this publication may be produced, stored in a retrieval system or transmitted in any form, electronic, mechanical, photocopying, recording or other means without prior written permission of Land Rover Limited, Service Department, Solihull, England
iv

HEATER

80

REMOVE FROM VEHICLE 1. Remove bonnet and disconnect battery. 2. Remove radiator bottom hose at radiator union and drain cooling system. 3 . Slacken and remove the heater hoses at heater box unions. 4. Remove outer cable securing clips. 5. Slacken and remove control cables at the heater box. 6. Remove heater wiring harness securing loop. 7. Disconnect harness multi-plug. 8. Remove interior bulkhead trim.

. ..

ST1887M

OVERHAUL Fan Motor Assembly

12. Remove the nuts securing the angled bracket to t h e heater unit, and remove the bracket. 13. Remove the five nuts securing the fan asscmbly to the heater unit. Unplug thc connector and remove the fan assembly [rom the heater unit. 14. Remove circlip holding the impeller to thc drive shaft and remove the impeller. 15. Remove the three nuts securing the fan motor to the mounting plate and release the m o t o r from the plate.

9. Remove lower nuts and bolts securing the heater unit to the bulkhead. 10. Slacken heater unit upper retaining bolts. 11. Manoeuvre heater unit clear of engine bay.

., .. . , .
-

80

HEATER
35. Connect harness multi-plug. 36. Refit control cable outer clip and inner cable pinch bolts. 37. If necessary, prime heatcr matrix with coolant mixture.

16. Fit fan motor into mounting plate, apply Rostik 1261 adhesive to mating faces, and secure with the three nuts. 17. Refit impeller to fan drive shaft and fit circlip. 18. Refit fan assembly to casing and secure with t h e five nuts. 19. Plug in connector to resistor harness and refit angled bracket. Heater Matrix 20. Drill out rivets holding the air duct and top covcr to the casing. (Three of the rivets are concealed by the rubber seal).

22 \

ST1888M

'W

38. Conncct hoses to hcater unit and tighten hose clips. 39. Refit radiator bottom hose and refill cooling system with the required anti-freeze concentration or corrosion inhibitor. 40. Refit bonnet. 41. Connect battery, start cnginc, and check for leaks. 42. After engine has cooled check coolant level in thc expansion tank and radiator. Top up if necessary.

21. Lift off cover, air duct and seal. 22. Lift heater matrix out of casing. 23. Fit foam rubber to heater matrix casing and position matrix in casing. 24. Check that flap valves operate correctly and without sticking. 25. Refit top cover and rivet into place.

Resistor Unit 26. Drill out the four rivets retaining the resistor mounting plate, and lift out plate with resistor. 27. Apply Bostik adhesive to resistor plate and secure in position with rivets. REFIT TO VEHICLE 28. Smear heater unit sealing rubber with a suitable impact adhesive, and locate to heater. 29. Piace neater unit into engine bay and manouevre into position on bulkhead. 30. Loosely fit lower heater unit nuts and bolts. 31. Tighten heater unit upper securing bolts. 32. Tighten lower nuts and bolts. 33. Refit interior bulkhead trim. 34. Locate heater wiring harness into securing loop, and tighten nut. 2

fl .

i'. I .

..

h,4 '.
I -

General Service Information INTRODUCTION Before any component of thc air conditioning system is removed, the system must be depressurised. When the component is replaced, the system must be evacuatcd to remove all traces of old refrigerant and moisture. Then the system must be recharged with new refrigerant. Any service operation that requires the loosening of a refrigerant line connection should be performed only by qualified service personnel. Refrigerant and/or oil will escape whenever a hose or pipe is disconnected. All work involving the handling of refrigerant requires special equipment, a knowledge of its proper use and attention to safety measures.

DO NOT - leave refrigerant drum without its heavy cap fitted. - carry refrigerant drum inside a vehicle. - subject refrigerant drums to high temperature. - weld or steam clcan near an air conditioning system. - expose eyes to liquid refrigerant, ALWAYS wear goggles. - discharge refrigerant vapour into an area with an exposed flame or into an engine intake. Heavy concentrations of refrigerant in contact with naked flame produces a toxic gas. - allow liquid refrigerant to contact bright metal, it will tarnish metal and chrome surfaces, and combined with moisture can seriously corrode all metal surfaces.

Servicing equipment The following equipment is required for full servicing of the air conditioning system. Charging trollcy Leak detector Tachometer Safety goggles Refrigerant charging line gaskets Thermometer -20C to -60C Valvc Core Removers PRECAUTIONS LINES WARNING: Always wear safety goggles when opening refrigerant connections. (a) When disconnecting any pipe or flexible connection the system must be discharged of all pressure. Proceed cautiously, regardless of gauge readings. Open connections slowly, kccping hands and face well clear, so that no injury occurs if there is liquid in the line. If pressure is noticed, allow it to bleed off slowly. (b) Lines, flexible end connections and componcnts must be capped immediately they are opened to prevent the entrance of moisture and dirt. (c) Any dirt or grcase on fittings must be wipcd off with a clean alcohol dampened cloth. Do not use chlorinated solvents such as trichloroethylene. If dirt, grease or moisture cannot be removed from inside the pipes, they must be replaced with new pipes. (d) All replacement components and flexible end connections arc sealed, and should only be opencd immediately prior to making the connection. (e) Ensure the components are at room temperature before uncapping, to prevent condensation of moisture from the air that enters. ( f ) Components must not remain uncapped for longer than fifteen minutes. In the event of delay, the caps must be repiaced. (g) Receiveddriers must never be left uncapped as they contain Silica Gel crystals which will absorb moisture from the atmosphere. A receiveddrier left uncapped must be replaced, and not used. (h) The compressor shaft must not be rotated until the system is entirely assembled and contains a charge of refrigerant.
1

IN HANDLING REFRIGERANT

SERVICING MATERIALS Rcfrigerant: Refrigerant 2, which includes Freon 2 or Arcton 2. CAUTION: Methychloride refrigerants must not be used. Nominal charge weight: 1,25 kg (2.75 Ibs). Compressor oil: See Recommended Lubricants.

PRECAUTIONS IN HANDLING REFRIGERANT The refrigerant used in the air conditioning system is Refrigcrant 2, and is transparent and colourless in both the gaseous and liquid statc. It has a boiling point of -2?.8OC (-21 2F) a t atmospheric p:essre m? a: all normal pressures and temperatures it becomes a vapour. The vapour is heavier than air, non-flammable, and non-explosive. It is non-poisonous except when in contact with an open flame, and non-corrosive until it comes in contact with water. The following precautions in handling Refrigerant 12 should be observed at all times.

. , ...,: . . , : . . .. .,
I .

il z

AIR CONDITIONING - L.H. & R.H. STEERING

Evaporator Examine the refrigeration connections at the unit. If the system should develop a fault, or if erratic operation is noticed, refer to the fault diagnosis chart.

(j) A new compressor contains an inital charge of 312,s ml (11 UK fluid ozs) of oil when received, part of which is distributed throughout the system when it has been run. The compressor contains a holding charge of gas when received which should be retained until the hoses are connected. (k) The receiveddrier should be the last component connected to the system to ensure optimum dehydration and maximum moisture protection of the system. (I) All precautions must be taken to prevent damage to fittings and connections. Slight damage could cause a leak with the high pressures used in the system. (m) Always use two spanners of the correct size, one on each hexagon, when releasing and tightening refrigeration unions. Joints and O rings should be coated with refrigeration oil to aid correct seating. Fittings which are not lubricated with refrigerant oil are almost certain to leak. All lines must be free of kinks. The efficiency of the system is reduced by a single kink or restriction. Flexible hoses should not be bent to a radius less than ten times the diameter of the hoses. Flexible connections should not be within 50 mm (2 ins) of the exhaust manifold. Completed assemblies must be checked for refrigeration lines touching sheet metal panels. Any direct contact of lines and sheet transmits noise and must be eliminated.

Service valves There are two types of service valves in operation: Stem and Schrader. To identify where the different operations occur, stem type will be boxed.

Stem type Stem type service valves allow for the isolation of the compressor from other parts o l the system. When these valves are used in conjunction with the liquid line quick-disconnect fittings, the three major assemblies of the system can be removed from the vehicle with a minimal loss of refrigerant. In addition, it is possible to remove major assemblies for repair of components which are not part of the refrigeration system, or provide access to parts of the vehicle which are obstructed by the air conditioning system, without fully discharging the system. A thormgh understanding of the stem type service valve is necessary before undertaking servicing or repair involving the air conditioning system.

~ - . ~

4--

PERIODIC MAINTENANCE Routine servicing apart from visual checks, is not necessary. The visual inspections are as follows:

Condenser With a hose pipe or air line, clean the face of the condenser to remove flies, leaves etc. Check the pipe connections for signs of oil leakage.

5
4
ST1387M

Compressor Check hose connections for signs of oil leakage. Check flexible hoses for swelling. Examine the compressor belt for tightness and condition. Checking the compressor oil level and topping-up is only necessary after charging the system or in the event of a malfunction of the system. Stem type service valve 1 Serviceport 2 Valve stem 3 Compressor port 4 Valve seat 5 Hose connector

ReceivedDrier Examine the sight glass for bubbles with the system operating. Check connections for leakage. 2

AIR CONDITIONING - L . H .
2 d.:,

R . H . STEERING

182

'.
k

NOTE: A special wrench should be used to adjust the valve to prevent damage to the stem.

The stem type service valve has three positions, the operation of which is explained as follows.

A. ON: FULLY ANTICLOCKWISE - Normal operating position, and the position which is used for connecting and disconnecting the manifold gauge set, is t h e on position. The stem is turned fully anticlockwise. This seals the service gauge port from receiving any refrigerant flow.

B. MID (Test) POSITION - After the service gauge manifold has been installed (the valve stem is in the on position), turn the valve stem the required number of turns clockwise. This will put the valve stem seat midway in thc service valve and allow full system operation while permitting refrigerant pressure to reach the gauges.

C. OFF: FULLY CLOCKWISE - With t h e service valve stem turned fully clockwise, the valve will block passage of refrigerant flow through the system. As illustrated, the refrigerant flow to or from the compressor (depending on whether it is high side or low side) is blocked.

ST1386M

WARNING: NEVER operate the air conditioning system with the service valves in the OFF POSITION, it will cause severe damage to the compressor.

AIR CONDITIONING -L.H. & R.H. STEERING

Schrader Type These are secured to the head of the compressor, and the suction and discharge flexible end connections are secured to them by unions. The service valves are identified as suction or low pressure, and discharge or high pressure. Whilst they are identical in operation they are not interchangeable, as the connections are of different sizes. The valve with the larger connections fits the suction side. As the name suggests, these valves are for service purposes, providing connections to external pressure/ vacuum gauges for test purposes. In combination with charging and testing equipment they are used to charge the system with refrigerant.

B. OFF: FULLY CLOCKWISE - With the service

valve stem turned fully clockwise, the valve will block passage of refrigerant flow through the system. As illustrated, the refrigerant flow to or from the compressor (depending on whether i t is high side or low side) is blocked. WARNING: NEVER operate the air conditioning system with the service valves in the OFF POSITION, it will cause severe damage to the compressor.

Valve Core Remover Where Schrader Valve depressors are not fittcd to the Testing equipment lines Valve core removers can be used.

Schrader service valve

Valve Core Removal The use of valve core removers will facilitate servicing operations and should be used as follows: 1. Close all valves on the charging trollcy. 2. Remove the service valve cap and seals from the valve core remover. 3. Withdraw the plungcr as far as possible and connect the core remover to the service valve. 4. Connect the hose to the core remover. 5. Dcpress the plunger until it contacts the valve core. Unscrew the valve until it is free. Withdraw the plunger to its full extent. Service valve caps must be replaced when service operations are completed. Failure to replace caps could rcsult in refrigerant loss and system failure.

ST1496M

1. 2. 3. 4. 5.

Valve stem Hose connection Service valve Schrader valve core Compressor port

9
3
ST1497M

NOTE: A special wrench should be used to adjust the valve to prevent damage to the stem.

The Schrader type service valve has two positions, the operation of which is explained as follows. A. ON: FULLY ANTICLOCKWISE - Normal operating position, and the position which is used for connecting and disconnecting the manifold gauge set, is the on position. The stem is turned fully anticlockwise. rl'his seals the service gauge port from receiving an, refrigerant flow.
4

AIR C O N D I T I O N I N G - L.H. & R.H. S T E E R I N G

ELECTRICAL CIRCUIT DIAGRAM

Key to Circuit Diagram

1. Thermostat 2 Condenser fan relay 3. 5 amp fuse 4. 17 amp fuse 5 . Compressor clutch relay 6 . L.H. fan 7. R.H. fan 8. High pressure switch 9 Compressor clutch temperature switch 10. Compressor clutch 11. Fan temperature switch 12. Blower fan relay 13. Diode - Diesel engines only 14. Termination point* 15. Ignition feed pick-off point 16. Starter solenoid pick-off point 17. 30 amp fuse 18. 30 amp fuse 19. Fan speed selector switch Wiring U = 1st speed R = 2ndspeed NOTE: R.H. steering models have only three fan speeds 0 = 3rdspeed Y = 4thspeed 20. ielay 21. 9ir conditioning on/off switch 22. Evaporator motor 23. Resistor block

* denotes: L.H. petrol, L.H.1R.H. diesel models, termination at starter solcnoid.

R.H. petrol models, termination via link lead to ignition switch.
Key to cable colours
B Black

G Green

K Pink

L tight

N Brown

0 Orange

P Purple

R Red

S Slate

U Blue

W White

Y Yellow

The last letter of a colour code denotes the tracer colour

82 I

AIR CONDITIONING -L . H . & R . H . STEERING

ELECTRICAL AIR CONDITIONER BLOWER MOTOR AND CONTROL SYSTEM DIAGNOSIS
BLOWER MOTOR OPERATES BLOWER MOTOR INOPERATIVE

INSPECT RESISTOR BLOCK

INSPECT FUSE

RESISTOR BLOCK

RESISTOR BLOCK OK

INSPECT BLOWER RESISTOR BLOCK

c 1 CHECK FOR BATTERY 1

I
f
MOTOR OK

REPLACE SWITCH IF DEFECTIVE

I
VOLTAGE AT BOTH ENDS O F FUSE

CHECK FOR STALLED MOTOR

f
MOTOR STALLED

t
REPLACE MOTOR

VOLTAGE AT BATTERY SIDE ONLY

CHECK FOR SHORT CIRCUIT AND CORRECT

CHECK MOTOR GROUND

REPLACE FUSE

+I

BETWEEN MOTOR GROUND

MOTOR RUNS

LOCATE OPEN CIRCUIT

ATTACH JUMPER WIRE FROM MOTOR FEED WIRE TO BATTERY POSITIVE POST

MOTOR DOES NOT RUN

f
MOTOR RUNS

f
REPLACE M O T O R

CHECK RESISTOR CONTINUITY AND CONNECTIONS

CHECK VOLTAGE A T RESISTOR CONNECTION A T A L L SWITCH POSITIONS 1 I

I
VOLTAGE AT ALL SWITCH POSITIONS
-~
~

I I

+
f

NO VOLTAGE IN O N E OR MORE SWITCH POSITIONS

REPLACE RESISTOR

1 I

REMOVE CONNECTOR FROM SWITCH AND CHECK FOR VOLTAGE A T BATTERY TEKMINAL

TERMINAL LOCATE OPEN CONNECTION AND CORRECT

VOLTAGE A T B A I T E R Y TERMINAL

f
REPLACE SWITCH

A I R CONDITIONING -L.H. & R . H . STEERING

.* a - . ~
I.

1821

>-

<di"

Refrigeration System Fault Diagnosis For any refrigeration system to function properly all components must be in good working order. The unit cooling cycle and the relationship between air dischdrge temperature and ambient temperature and the pressures at the compressor can help to determine proper operation of the system. The length of any cooling cycle is determined by such factors as ambient temperature and humidity, thermostat setting, compressor speed and air leakage into the cooled area, etc. With these factors constant, any sudden increase in the length of the cooling cycle would be indicative of abnormal operation of the air conditioner. The low and high side pressures at the compressor will vary with changing ambient temperature, humidity, cab temperature and altitude. The following conditions should be checked after operating the system for several minutes: 1. All high side lines and components should be warm to the touch. 2. All low side lines should be cool to the touch. 3 . Inlet and outlet temperatures at the receiveddrier should be at the same temperature (warm). Any very noticeable temperature difference indicates a blocked receiveddrier. 4. Heavy frost on the inlet to the expansion valve may indicate a defective valve or moisture in the system. 5 . With ambient humidity between 30% and 60%, compressor pressures and evaporator air discharge temperature should fall within the general limits given in the table below.

Type of Weather

Evaporator Air Temp "F ("C)

I

Low Side Pressure Ib/inz (Kg/cmz)

1
I

High Side Pressure Ib/inz (Kg/cmz)

I
Cool Day 70OF-80"F (21-27C)
~~

I
15-20 (1.1-1.4) 160-200 (11.2-14)

35-45F (1.7-7.2"C)

Warm Day 80"F-90F (27-32C)

J

40-50F (4.4-10C)

20-25
(I .4-1 .8)

190-240 ( 13.4-16.9)

Over 90F (Over 32C)

* 4,
+

45-60F (7.2-15.6"C)

25-30 (1.8-2.1)

220-270 (15 5 1 9 )

NOTE: 1. Low and high side pressures are guides not specific limits. 2. Evap. air temperatures will be lower on dry days, higher on humid days.
7

1821

A I R CO N D ITI O N I NG -L.H. & R . H . STEERING

FAULT
A. H I G H H E A D PRESSURE 1.

CAUSE
Overcharge of refrigerant. Air in system. Condenser air passage clogged with dirt or other foreign matter. Condenser fan motor defective. Undercharge of refrigerant; evident by bubbles in sight glass while system is operating. Split compressor gasket o r leaking valves Defective compressor Slack compressor belt. Refrigerant flooding through evaporator into suction line; evident by ice on suction line and suction service valve. Expansion valve stuck open. Compressor suction valve strainer restricted. Leaking compressor valves, valve gaskets and/or service valves. Rcceiveddrier stopped; evident by temperature difference between input and output lines. Expansion valve thcrmobulb not operating. Expansion valve sticking closed
1.

REMEDY
Purge with bleed hose until bubbles start to appear in sight glass; then, add sufficient refrigerant gas to clear sight glass. 2. Slowly blow charge to atmosphere. Install new drier; evacuate and charge system. 3. Clean condenser of debris. 4. 1. 2. Replace motor. Evacuate and recharge the system. Check for leakage. Replace gasket and install new drier, evacuate, and charge the system. Replace compressor.

2. 3. 4. B. L O W H E A D PRESSURE

I.
2. 3.

3.

C. HIGH SUCTION PRESSURE

1. 2.

3.
4.

5.
6.

1. Adjust belt tension. 2 . Check thermobulb. Bulb should be securely clamped to clean horizontal section of copper suction pipe. 3. Replace expansion valve. 1. Replace compressor. 5 . Replace valves and/or gaskets. Install new drier, evacuate, and charge the system. 5 . Install new drier, evacuate and charge the system. Warm thcrmobulb with hand Suction should rise rapidly to 20 Ibs. or more. If not, replace expansion-valve. ?. Check inlet side screen. Clean if clogged. Refer to C-2 and C-3. 3. Install new drier, evacuate and charge the system. periodically. i. Clean grilles as required.
I
j.

5. L O W SUCTION

1.

2.

Moisture freezing in expansion vaivc orifice. Valve outlet tube will frost while inlet hose tube will have littlc or no frost. System operates 1. Dust, paper scraps, o r other debris restricting evaporator blower grille. 5 . Dcfcctivc evaporator blower motor, wiring, o r blower switch.

3.

Refer to Fault Diagnosis for Elcctrical System.

E. NOISY EXPANSION
VALVE (steady hissing) F. INSUFFICTENT COOLING

I.

Low refrigerant charge; evident by bubbles in sight glass. Expansion valve not operating properly. Low refrigerant charge; evident by bubbles in sight glass. Compressor not pumping.

. Leak test. Repair o r replace components as

required.

I. !.

!.
i.

. Refer to C-2, C-3, D-2. D-3 and E. Refer to B-1 and E .

Refer to B-2 and 8-3

I.
G . COMPRESSOR BELT

! . Belt tension !. !.

Excessive head pressure. Incorrect alignment of pulleys o r worn belt not riding properly. 1. Nicked o r broken pulley. i. Frozen compressor.

With tension gauge adjust to 100 Ibs. (45 kg); or tighten until depression of about 'Ainch (1,25 cm) occurs across longest span. !. Refer to A-1 through A-4 and C-6. 1. Repair as needed.
. ._ Replace pulley.
8.

Replace comprcssor.
~ _ _ _ _ ~ ~

H. ENGINE NOISE ANDiOR VIBRATION

Loose or missing mounting bolts. Broken mounting bracket, idler bracket, or brace. i. Loose llywheel or clutch retaining boit. i. Rough idler pulley bearing. ;. Bent, loose, o r improperly mounted engine drive pulley. Incorrect installation of clutch bearing seal. 1. ' _ Insecure mountings of accessories: gcncrator, power steering, air filter, etc. I. Excessive head pressure. 1. Incorrect compressor ail.
. !.

Repair as necessary. .. Replace defective part.

.
'.

. Replace bearing. . Repair as necessary. . Repair as necessary . Refer to A - I , A-2, A-3, A-4 and C-6. . Refer to Compressor Oil Level Check.
Replace bearing.

Repair as necessary.

#,

AIR CONDITION NG - L.H. & R . H . STEERING

(821

COMPRESSOR AND CLUTCH DIAGNOSIS

COMPRESSOR CLUTCH WILL NOT ENGAGE

NO VOLTAGE AT CLUTCH

.
OPEN FUSE PUSH-BUITTON SWITCH DEFECTIVE

+
I

VOLTAGE AT CLUTCH LOW

OPEN

CLUTCH-COIL~
7

REPLACE COIL

I
I

v J
POOR CLUTCH GROUND
CYCLING CLUTCH SWITCH IF CONTACT OPEN REPLACE SWITCH

FAULTY WIRING

COMPRESSOR WILL NOT TURN PROPERLY CLUTCH ENGAGES BUT SLIPS OR SMOKES

t
CLUTCH-SLIPPING

1
L

I I c I
LOW VOLTAGE A T CLUTCH

SEIZEDCOMPRESSOR

- 4 1 I I
BELTS SLIPPING

II

REPLACE COMPRESSOR AND CLUTCHASSEMBLY

I I
I t

ADJUST BELT TO PROPER TENSION

I
REPLACE CLUTCH COIL
9

CLUTCH COIL PARTIALLY SHORTED

1821

A I R C O N D T T I O N I N G - L.H. & R.H. S T E E R I N G MECHANICAL AIR CONDITIONER BLOWER MOTOR AND CONTROL SYSTEM DIAGNOSIS

LOWER MOTOR OPERATIV

i I
MODE CONTROL LEVER I N DE-MIST POSITION
I

*I

ENGTNE RUNNING T O PROVIDE VACUUM

-1

MODE CONTROL LEVER IN

FLOOR DUMP POSTTION

MODE CONTROL LEVER IN FASCIA OUTLET POSITION

I

.c

c
I
FAULTY BLOWER WHEEL

NO DISCHARGE AIR FROM DE-MIST OUTLETS

NO AIR FROM FASCIA LOUVRES

+
f
AIR DISCHARGE A T FASCIA FAULTY MODE DOOR

II

c
FAULTY MODE DOOR ACTUATOR
I
I

FAULTY MODE DOOR VACUUM SWITCH

NO AIR DISCHARGE FROM FLOOR DUMPS

DOOR OPERATING LINK DISCONNECTED A T CONTROL LEVER OR FLOOR DUMP DOOR

1
I

BLOWER MOTOR AND PASSENGERCOMPARTMENT AIR CONTROL OPERATIVE

H O T WATER VALVE
1 1

INSUFFICIENT HEATING
I

*
I

TEMPERATURE CONTROL INOPERATIVE

INSUFFICIENT COOLING
I
I

HOT WATER VALVE VACUUM SWTTCH MIS-ADJUSTED

I

BLEND AIR DOOR BOWDEN CABLE DISCONNECTED A T CONTROL LEVER O R AT DOOR CRANK

I I
HOT WATER VALVE VACUUM SWITCH MIS-ADJUSTED
H O T WATER VALVE STUCK IN OPEN POSTTTON VACUUM LINE PINCHED O R DISCONNECTED FROM ACTUATOR O R SWITCH

1
HOT WATER VALVE STUCK IN CLOSED POSITION VACUUM LINE PINCHED

CLAMP SLIPPING

BLEND ATR DOOR MIS-ADJUSTED

10

AIR CONDITIONING -L.H. & R.H. STEERING

e

1821

L. .z

.::.

CHARGING AND TESTING EQUIPMENT Connecting the gauge set NOTE 1: There are two methods of connecting the charging and testing equipment, depending on the operation to be carried out. The method described for evacuating or charging with liquid refrigerant also applies to pressure test and compressor oil level check operations. NOTE 2: Various types of charge and test equipment are available depending upon the manufacturer chosen by the user. The equipment illustrated may differ slightly in layout to that possessed by the user, however, it is recommended that the user adheres to the appropriate manufacturers instructions for the charge and test equipment used in their workshop.

ST 1393M

-NOTE: The boxed instructions in the following procedure refer to compressors with STEM type valves. All other instructions refer to SCHRADER type valves.

Fitting

1. Ensure that all the valves on the charging and testing equipment are closed. Control valves on the particular equipment selected are numbered 1 to 4 as illustrated. The sequence may vary on other proprietary equipment. 2. Mount a 11,3 kg (25 Ib) drum of refrigerant upside down on the support at the rear of the charging equipment, and secure with the strap.

6. Place the vehicle in a ventilated area away from open flames and heat sources. Stop the engine, open and secure the bonnet. 7. Check that both service valves are fully opcn (turned anti-clockwise). 8. Put on the safety goggles. 9. Remove the caps from the gauge connections on the service ports. 10. Coat the threads and flares with refrigerant oil. 11. Connect the low pressure charging line (blue) from valve No. 1 to the comprcssor suction service port. 12. Connect the high pressure charging linc (rcd) from valve No. 2 to the compressor discharge scrvicc port.
13. Using the service wrench, turn the suction service valve stem clockwise counting the number of turns necessary to close the valve.

ST 1392M

ST 1412M

3. Connect the hose from the bottom of the charging cylinder to the refrigerant drum valve. 4. Connect the hose between the bottom of the charging cylinder and the refrigerant control valve (No. 4). 5. Connect the hose between the vacuum pump valve and the vacuum control valve (No. 3).

i
14. After the valve is fully closed, turn the stem

out (anti-clockwise) half the number of turns counted, this should position the valve seat in the mid (test) position.

11

182I

A IR CONDITIONING -L . H . & R . H . STEERING

1. Place the vehicle in a ventilated area away from open flames and heat sources. 2. Stop the engine. 3. Open and secure the bonnet. 4. Remove the caps from thc compressor service ports. 5 . Check that both compressor service valves are fully opened (turned anti-clockwise). 6. Close all valves on t h e charging and testing equipment. 7. Put on safety goggles. 8. Connect the high pressure charging line (red) from valve No. 2 to the compressor discharge service port. 9. Run the (blue) hose to an open tapped container of approximately one litre capacity. Attach the hose to the container so that it will not blow out of the container. The purpose of the container is to collect any oil carried by the refrigerant.
*p-3.

15. Turn the stem on the discharge valve clockwise until the pressure rises on the discharge pressure gauge. If the system is to be evacuated, the discharge service valve seat

16. The charging and testing equipment is now connected and ready for proceeding with the required operation.

Removing

17. If the engine has been operated, it must be stopped prior to disconnecting the charging and testing eq U i pm en t . 18. Close both service ports (turn fully anti-clockwise) until fully closed. 19. Close all valves on t h e charging and testing equipment. 20. Disconnect the charging lines from the service ports. 21. Refit the blanking caps to t h e compressor valve stems and service ports, and to the charging lines. 22. Close the bonnet.

10. Open the compressor discharge service port a quarter of a turn.

11. Open valve No. 2 fully. 12. Slowly open t h e valve No. 1 one turn to allow the refrigerant to escape, if necessary, adjust the refrigerant flow so that the oil captured in t h c container is not blown out of the container.

6,,-

1 2

11

AIR CONDITIONING SYSTEM OPERATIONS

Depressurising NOTE: The air conditioning refrigeration system contains Refrigerant 12 under pressure, and before any component is disconnected or removed, the system must be discharged of all pressure. Refrigerant 12 evaporates so rapidly at normal atmospheric pressures and temperatures that it tends to freeze anything it contacts. Extreme care must be taken to prevent any liquid refrigerant from contacting the skin and especially the eyes. Should any liquid refrigerant get into the eyes, use a few drops of sterile mineral oil to wash them out and then wash the eyes with a weak solution of boric acid. Seek medical attention immediatcly even though the initial irritation has ceased aftcr first aid treatment. Always wear safety goggles whea epeaing refrigerant cnnnections.

ST 1413M

13. Measure the amount of oil discharged from the system so that an equal amount of new oil can bc returned to the system during the charging operation. Discard the old oil. 14. When the gauge pressure is below 50 psi, slowly open the valve No. 1 to maintain refrigerant flow. 15. When the pressure has been reduced, and the system has been completely discharged, close the valves Nos. 1 and 2 on the charging and testing equipment.

WARNING: Open connections slowly, keeping the

16. Close the compressor discharge service port (turn anti-clockwise).

--.

AIR CONDITIONING - L.H. & R.H. STEERING

*F>,
I

4"..;

NOTE: If it is necessary to disconnect the compressor hoses, the compressor should be sealed by fully closing the relevant service valve (turn fully clockwise). It is essential to ensure that both service valves are open before operating the compressor. Similarly any other component of the refrigeration system should be capped immediately when disconnected.

1. Depressurise the air conditioning system as previously described, then conncct the gauge set as detailed under 'Charging and Testing Equipment'. 2. Adjust both service valve seats to the mid (Test) position.

18. Open the refrigeration drum valve. 19. Open the valve at the base of the charging cylinder and allow approximately 0,25 kg (0.5 Ib) of refrigerant to enter t h e cylinder. 20. Close the refrigeration drum valve and the valve at the base of the charging cylinder. 21. Open the refrigerant control valve (valve No. 4) and flush out the high and low pressure lines by opening valves Nos. 1 and 2 momentarily until a white stream of refrigerant is observed.

3. Open the low and high pressure valves Nos. 1 and 2. 4. Start the vacuum pump and check that thc vacuum pump valve is open. 5. Slowly open the vacuum control valve No. 3. If the vacuum is applied to the system too quickly, the residual oil may bc drawn out.

4
ST 1394M

ST 1414M

22. Close all valves on t h e charging and testing equipment, and fit the blanking caps. 23. The air conditioning system is now depressurised.

6. In evacuating the system i t is necessary to lower the pressure so that the boiling point of water in the system is lower than the surrounding air tempcrature. At an ambient temperature of 23.S"C (75"F), it is necessary to lower t h e system pressure to 29.5 in Hg vacuum to bring the boiling point of water to 22C (72F). Atmospheric prcssure (and vacuum gauge readings) decrease as altitude increases by approximalcly 25 mm ( I in) IIg per 300 m (1000 ft). The following chart provides a guide to the various gauge readings at diflering altitudes, for the same 10 mm (0.4 in) Hg absolute pressure. Altitude, f t 0 1,000 2,000 3,000 4,000 5 ,GUU 6,000 7,000 8,000 9,000 10,000
m
Vacuum Reading in Hg

0 300 600

Evacuating Whenever the system has becii ~ p e i i e b io iiie atmosphere it is necessary that the system be evacuated to remove all air and moisture. I t is also an essential preliminary operation to charging the system with Refrigerant 12. The evacuate operation also provides a check for leaks due 10 faulty connections.

900
1200 i 5Oii 1800 2100 2400 2700 3000

:::

2 .

29.5 28.5 27.4 26.4 25.4 24.5 23.5 22.6 21 .a 20.9 20.1

mm 750 725 695 670 645 622 596 574 554 530 510 13

82

A IR C O N DITI O N I N G -L . H . & R . H . STEERING

Sweeping

7. The low side gauge should indicate a vacuum of 660 mm (26 in) Hg within five minutes. 8. Whilst the system is evacuating, fill the charging cylinder by opening the refrigerant drum valvc. 9. Open the valve at the base of the charging cylinder and fill the cylinder with 1,0 kg (2.2 Ib) of refrigerant. Liquid refrigerant will be observed rising in the sight glass. 10. As the refrigcrant stops filling the cylinder, opcn the valve at t h e top of t h e cylinder (behind the control panel) intermittently, to relieve the head pressure and allow the refrigerant to continue filling the cylinder. 11. When the refrigerant reaches the desired level in the sight glass, close both the valve at the basc of the cylinder and the valve at the bottom of the refrigerant tank. 12. Ensure the top cylinder valve is fully closed. If bubbling is present in the sight glass, reopen the cylinder base valve momentarily to equalise the drum and cylinder pressures. 13. If 660 mm (26 in) Hg of vacuum is not achieved within fivc minutes, it signifies either the system has a leak or thc vacuum pump is dcfcctive. Initially check thc vacuum pump, if thc pump proves to be functioning properly then investigate for a leak in thc air conditioning system. 14. Close t h c vacuum control valve No. 3. 15. Stop t h e vacuum pump and allow the vacuum to hold for fifteen minutes, then check that there is no pressure rise (a loss of vacuum) evident on the compound gauge. Any pressure rise denotes a leak which must be rectified before procccding further. Refer to the heading titled Leak Detection later in this section. 16. With thc system satisfactorily evacuated, the system is ready for charging with refrigerant.

NOTE: This operation is in addition to evacuating, and is to remove moisture from systems that have been open to atmosphere for a long period, or that are known to contain excessive moisture.

1. Fit a new liquid receiver/dricr, as detailed undcr the heading Receiver/Drier. 2. Ensure that a full drum of refrigerant is fitted on the charging and testing equipment. 3. Fit the charging and testing equipment as previously described for evacuating and evacuate the air conditioning system, allowing 0,25 to 0,45 kg (h to 1 Ib) of refrigerant to enter the charging cylinder. 4. Close all valves on the charging and testing equipment. 5 . Disconnect the intake hose from thc vacuum Pump.

ST 1396M

% y*
6. Connect thc intake hose to thc valve at the top of the charging cylinder. 7. Open the valve at the top of the charging cylinder. 8. Put on safety goggles, 9. Crack open the hose connection at valve No. 3 and allow some refrigerant to purge t h e hose, then close the connection. 10. Open the high pressure valve (No. 2). 11. Slowly open valve No. 3, which is now connected to the top valve of the charging cylinder, and allow gas to flow into the system until the reading on the compound gauge remains steady. Between 0,25 and 0,45 kg (I/? to 1 Ib) of refrigerant will entcr the system. 12. Allow the dry refrigerant introduced into the system to remain for 10 minutes.

n:

ST 1395M

14

A IR CONDITIONING - L.H. & R . H . STEERING

i(
1 .

IS21

13. Crack the suction valve charging line at the service port on the compressor to allow an escape of refrigerant, at the same time observing thc sight glass in the charging cylinder. A slight drop in the level should be allwwed before closing the connection at the compressor. 14. Close the high pressure valve (No. 2 ) . 15. Close valve No. 3. 16. Close the valve at the top of the charging cylinder.

6. If the full charge of 1,0 kg (2.2 Ib) of liquid

refrigerant will not enter the system, then close the high pressure valve (No. 2) and open the low pressure valve (No. l), ensuring that the low pressure gauge does not exceed 40 psi. 7. Start and run the engine at 1,000-1,500 rev/min and allow refrigerant to be drawn though the low pressure valve (No. 1) until the full charge of 1,0 kg (2.2 Ib) has been drawn into the system. 8. Close valve No. 1.

14-10
6,

4-6

ST 1397M

"
ST 1398M

17. Reconncct thc charging and testing equipment, as described for evacuating and evacuate the air conditioning system. 18. Maintain the vacuum for twenty minutes. The air conditioning system is now ready for charging with refrigerant.

9. Check the air conditioning system is operating

satisfactorily by carrying out a prcssurc test, as described later in the Section. CAUTION: Do not overcharge the air conditioning system as this will cause excessive head pressure.

Charging CAUTION: Do not charge liquid refrigerant into the compressor. Liquid cannot be compressed; and if liquid refrigerant enters the compressor inlet valve, severe damage is possible; in addition, the oil charge may be absorbed into the refrigerant, causing damage when the compressor is operated. 1. Fit the charging and testing equipment as previously described for evacuating. 2 . Evacuate the air conditioning system allowing 1,0 kg (2.2 Ib) of refrigerant to enter the charging
rvlinrier
-J
'

Leak test The following instructions refer to an electronic type refrigerant leak detector which is the safest, most sensitive and widely used. 1. Place the vehicle in a well ventilated arca but free from draughts, as leakage from the system could be dissipated without detection. 2. Follow the instructions issued by the manufacturer of t h e particular leak detector being uscd. Certain dctectors have visual and audible indicators. 3 . Commence searching for leaks by passing the deiecioi pietie aiuund aii jwinis and components, particularly on the underside, as the refrigerant gas is heavier than air. 4. Insert t h e probe into an air outlet of the evaporator. Switch the air conditioning blower on and off at intervals of ten seconds. Any leaking refrigerant will be gathered in by the blower and detected.
15

3. Put on safety goggles. 4. Close the low pressure valve (No. 1). 5 . Open the refrigerant control valve (No. 4) and release liquid refrigerant into the system through the compressor discharge valve port (High pressure). The pressure in the system will eventually balance.

182I
6.
7.

AIR CONDITIONING -L. H . & R.H. STEERING

Test 1. Place the vehicle in a ventilated, shaded area free from excessive draught, with the doors and windows open. 2. Check that the surface of the condenser is not restricted with dirt, leaves, flies, etc. Do not neglect to check the surface between the condenser and the radiator. Clean as necessary. 3. Switch on the ignition and the air conditioner air flow control. Check that the blower is operating efficiently at low, medium and high speeds. Switch off the blower and the ignition. 4. Check that the evaporator condensate drains are open and clear. 5 . Check the tension of the compressor driving belt, and adjust if necessary. 6. Inspect all connections for the presence of refrigerant oil. If oil is evident, check for leaks, and rectify as necessary.

5. Insert the probe between the magnetic clutch and

compressor to check the shaft seal for leaks. Check all service valve conncctions, valve plate, head and base plate joints and back seal plate. Check the condenser for leaks at the pipe connections. If any leaks are found, the system must be depressurised before attempting rectification. If repairs by brazing are necessary, the component must be removed from thc vehicle and all traces of refrigerant expelled before heat is applied. After repairs check the system for leaks and evacuate prior to charging.

8.

9.

Pressure test

1. Fit the charging and test equipment as previously described. 2. Start the engine. 3. Run the engine at 1,000 to 1,200 rev/min with the heat control set to cold (blue) zone, air distribution to the central position, recirculation control to recirculation and the air conditioning control 'ON' with fan speed to maximum. 4. Note thc ambient air tcmpcrature control in the immediate test area in front of the vehicle, and check the high pressure gauge readings discharge sidc - against table 1.
Table I

NOTE: The compressor oil is soluble in Refrigerant 12 and is deposited when the refrigerant evaporates from a leak.

Compound Gauge High Pressure Ambient Readings Gauge Readings Temperature

"C

O F

kgf/cm2

Ibf/in2

kgf/cm2

Ibflin'

16 26,7 38 433

60 80 100 110

1,05-1,4 1,4-1,75 1,75-2,1 2,l-2,45

15-20 7,O-10,2 100-150 20-25 9,8-13,3 140-190 25-30 11,6-15.8 180-225 30-35 15,l-17,5 215-250

I 7, and close service portson(turn fully a,,ti-clockwise)/ Close both all valves the charging and test
equipment. Disconnect the charging lines from the compressor. Refit the blanking caps to the compressor valve stems, port connections and charging lines.

8. Close the bonnet. 16

7. Start the engine. 8. Set the temperature control switch to maximum cooling and switch the air conditioner blower control on and off several times, checking that the magnetic clutch on the compressor engages and releases each time. 9. With the temperature control at maximum cooling and the blower control at high speed, warm up the engine and fast idle at 1,000 rev/min. Check the sight glass for bubbles or foam. The sight glass should be generally clear after five minutes running, occasional bubbles being acceptable. Continuous bubbles may appear in a serviceable system on a cool day, or if there is insufficient air flow over the condenser at a high ambient temperature. 10. Repeat at 1,800 rev/min. 11. Gradually increase the engine speed to the high range, and check the sight glass at intervals. 12. Check for frosting on the service valves and evaDorator fins. i3. Check the 'nigh pressure pipes and connecrions by hand for varying temperature. Low temperature indicates a restriction or blockage at that point. 14. Switch off the air conditioning blower and stop the engine. 15. If the air conditioning equipment is still not satisfactory, proceed with the pressure test as previously described in this section.

AIR CONDITIONING- L.H. & R . H . STEERING

1821

./. .
/:.

,. I

COMPRESSOR
Removal

Petrol model

1. Place the vehiclc in a ventilated area away from open flames and heat sources. 2. Stop the engine and secure the bonnet in an open position. 3. Remove the caps from the compressor service valves and connect the gauge set for evacuating. 4. Evacuate the system as previously described. 5 . Open fully (turn anti-clockwise) the compressor service valves and disconnect the gauge set. Cap all pipe and valve connections to prevent dirt or moisture entering the system. 6 . Remove the electrical connections to the compressor.

- .
4-cylinder Petrol only
7 . Shckcn all the ComPressor adjustment fixin@ and remove the drive belt from the compressor. 8. Remove the adjusting and pivot fixings and the compressor from retaining bracket.

V8 models only
9. Release the jockey wheel adjuster to enable the front drive (fan) belt to be removed. 10. Release the tensioner on the compressor drive belt. 11. Remove the fixing bolt and swivel the compressor and bracket assembly t o expose the bolt which is securing the bracket. 12. Remove the bolt and lift the compressor and bracket clear and place on a bench. 13. Whilst supporting the compressor, remove the five bolts holding the compressor to the brackets.

Diesel model

8 -

ST1418M

All engines
14. N o servicing is recommended to the compressor, therefore a new unit must be fitted. 15. Reverse procedure as appropriate 13 to 9 and 6 to 3 for V8 models or 8 to 3 for 4-cylinder models noting the procedure for adjusting the compressor drive belts. 17

E l
Refitting

AIR CONDITIONING -L.H. & R.H. STEERING

24. Alter the position of t h e compressor to provide a belt tension of 4-6 mm (0.19-0.25 in). Secure all compressor adjustment bolts and recheck the tension. 25. Ensure the jockey pulley adjustment bolts are slack. 26. Alter the position of the jockey pulley to give a belt tension of 4-6 mm (0.19-0.25 in). Secure the adjustment bolts and recheck tension.

Drive belt adjustment Diesel only

16. Ensure all adjustment bolts associated with the compressor are slack. 17. Alter the position of the compressor to provide a belt tension of 4-6 mm (0.19-0.25 in). Secure all compressor adjustment bolts and recheck the tension.

ST1391M

CONDENSER FAN MOTORS

4-cylinder Petrol only Removal 18. Ensure all adjustment bolts associated with the compressor (1) and the lower pulley pivot fixing (2) are slack. 19. Adjust the position of the lower pulley to give a belt tension of 4-6 mm (0.19-0.25 in). 20. Tighten the pivot bolt and recheck the tension. 21. Alter the position of the compressor to provide a belt tension of 4-6 mm (0.19-0.25 in). 22. Secure all compressor adjustment bolts and recheck the tension.
1. Open and secure the bonnet. 2. Release the six self tapping screws securing the front nose and grille assembly, lift clear. 3. Disconnect the electrical leads to the fans. 4. Remove the blanking caps from the fan centres. 5. Remove the 8 mm securing nuts, star and spring washers from the fan blade centres, pull blade from its respective fan motor shaft. 6. Release t h e two fan motor retaining bolts and remove the motor whilst feeding the fan motor through the appropriate aperture.

ST1409M

ST 1401M

Refitting V8 Petrol only 23. Ensure all adjustment bolts associated with the compressor are slack.
18

7. Reverse procedures 6 to 1 ensuring the fan supply wiring is routed and securely clipped so that the wiring does not foul the fan blades.

2 ' .
f-y

A IR CONDITIONING- L.H. & R . H . STEERING

CONDENSER AND RECEIVER/DRIER Removal 1. Place the vehicle in a well ventilated arca. 2. Stop the engine, open and secure the bonnet. 3 . Remove the caps from the compressor service valves. Connect the gauge set for evacuation, and evacuate as detailed earlier. 4. Having evacuated the air conditioning system, open fully (turn anti-clockwise) the compressor service valves and disconnect the gauge set. Replace all caps to valve connections. 5 . Release the four top and two side fixings securing the grille and nose assembly and remove. 6. Disconnect the wires at the rear of the horn, the air conditioning fan leads located across the top of the fan cowling frame and the electrical connector to the receivddrier. 7. Release the four bolts and large packing washers securing the cowling to the wing sides. 8. Remove the four nuts securing the fan cowling to the bottom bracket and lift clear. 9. Remove the two bolts securing thc bonnet striker support plate.
~

1821

NOTE: L.H. steering vehicle illustrated on R.H. steering vehicles the high pressure hose is on the side of the evaporator unit facing the engine,
13. Release the high pressure pipe from the receiver/ drier, cap t h e pipc end connections.

Condenser removal only

10. Release the top air conditioning hose and cap the ends to prevent moisture and dirt entering the system.

610

7
S

7
11. Lift the condenser from the bottom mounting lugs and carefully ease the condenser forwards as far as possible. 12. .-.;t:, Release the high pressure air conditioning hose : .p. complete with the sight glass, at the evaporator connection. Cap the ends to prevent dirt or moisture entering the system.
.I...

14. Release both air conditioning pipes from the condenser extension plate. Lift the condenser clear.

Receiveddrier removal 15. Whilst supporting with suitable spanners, unscrew the b ~ t t ~ i mi ~ f ito the ieceii;eiidiiei. Lap the t fi pipe ends to prevent dirt or moisture entering the system. 16. Release the receiver/drier clamp bolts and allow the assembly to drop clear of the condenser. 17. Lift the receiveddrier from t h e condenser and discard. 11 is NOT recommended to refit the old unit. 19

->

1821

AIR CONDITIONING -L.H. & R . H . STEERING

EVAPORATOR -LH steering models

NOTE: It is only necessary to evacuate the air conditioning system when removing the evaporator matrix or to change the expansion valve.

Removal

1. Place the vehicle in a ventilated area away from open flames and heat sources. 2. Stop the engine and secure the bonnet in an open position.

Heater matrix and blower motor only 3. Remove the caps from the compressor service valves and close (turn clockwise) fully. 4. Disconnect the low pressure valve from thc compressor and cap both ends to prevent dirt or moisture entering the system. 5. Using two suitable spanners remove the high pressure pipe from the evaporator side. Cap both ends to prevent dirt or moisture entering the system.

/% -

'>--.

Refitting

18. Reverse procedures 17 to 15 using a new receiver/ drier unit. 19. Connect the high prcssurc pipe to the received drier. Using two spanners on each union, tighten the union noting that the sight glass remains in t h e vertical position. 20. Carefully locate the condenser into position, refit the fixings securing the condenser to the extension plate. Connect and tighten the air conditioning hose to the top of the condenser. Use two spanners on each union. 21. Refit the condenser to the bottom bracket. 22. Place the bonnet striker support plate into position, do not secure at this stage. 23. Fit the fan cowling support brackets. It will be necessary to lift thc bonnet striker support plate to permit the positioning of the fan cowling assembly to the condenser mounting lugs. 24. Secure the steady rods and the lower condenser mounting bracket. Do not tighten the bolts at this stagc. Reconnect the top horn electrical leads. 25. Loosely fit the four bolts and distance washers which support the bonnet striker support plate and fan cowling to the wing sides. 26. Tighten the lower condenser bracket bolts. 27. Adjust the condenser position with t h e bonnet striker support bracket assembly to obtain an equal distance from the radiator. Tighten the four side mounting bolts. 28. Tighten the four nuis and washers which sccure the fan cowling mounting. 29. Reconnect the electrical wiring for the fan assemblies, horn and receiveddrier. 30. Recheck the security of all fixings. 31. Refit the front nose and grille assembly and secure. 32. Evacuate, sweep and charge the air conditioning system as previously described. 20

Evaporator matrix and expansion valve only 6. Remove the caps from the Compressor service valves and connect the gauge set for evacuating.
7

/.

r.^^..^..+ .

C V d L U 4 1 G LIIG U11 LUllUlllul~1~l~ ~ c . 1 1LLJ y n c v n v u o ~ ~ 3ya 1

&, L.

-:..-,.-,4:+:--:-*

r.,r+om

op

*v,=.,,;n,,ci,,

described.

8. Open the compressor service valves and disconnect

the gauge set. Cap all pipes and gauge connections to prevent dirt or moisture entering the system. 9. Release the fixings and remove the expansion tank to provide access to the air conditioning high and low pressure pipes.
d-

: -

f ,-::: k;d'

AIR CONDITIONING -L . H . STEERING

:.-'
,

82

..

10. Whilst supporting both unions with suitable spanners unscrew the high and low pressure air conditioning pipes to the evaporator. Cap the pipe ends and evaporator inlets to prevent dirt or moisture entering the system.

18. Remove the screw, releasing the relay connector

block. 19. All wiring on the top of the evaporator is now disconnected with the exception of the earth lead, this is disconnected when the evaporator mounting block is removed. 20. Using suitable pipe clamps, clamp the inlet and outlet coolant pipes at the base of the evaporator and release the two jubilee clips and detach, or drain the radiator.

Evaporator unit

11. Disconnect the electrical leads fcedine the " compressor clutch cycling switch. 12. Detach the vacuum pipes from the water valve switch. 13. Remove the fixings securing the water valve switch and withdraw it. 14. Remove the clip and cable connection from the evaporator heater flap rod. Use a new clip on reassembly. 15. Release the nylon cable retainer. 16. Detach the heater electric supply lead at the connecting block. 17. Remove the relay from its connecting block revealing one self tapping screw.

21. From inside the vehiclc remove the front passenger carpet and self tapping screws which retain the toe-board. Remove t h e toe-board. 22. Release two bolts,

23. From inside the engine compartment remove the two upper evaporator mounting block bolts fitted to the engine bulkhead. This also releases the earthing leads. 24. Remove the bolt securing the angled bracket at the front of the evaporator casing.
21

I 1 AIR CONDITIONING -L.H. STEERING F

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45

ST1416M

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25. Lift the evaporator clear of the vehicle and place on a bench with a suitable support underneath the case t o ensure the heater pipes are not damaged. 26. Release the nuts and remove the bracket from underneath the evaporator casing. 27. Remove the wire clip and detach the dump valve located underneath. 28. Release the seven self tapping screws securing the outlet duct and carefully break the sealing compound around the edge of the duct and pull ducting plate away from evaporator body. 29. Remove the fifteen screws located around t h e cover seam, Remove the old sealing compound from the body and top cover. 30. Remove the four screws and four nuts from the top of the cover. 31. From the front of the unit remove the two screws adjacent to the low pressure pipe moulding. 32. At the side of the unit remove the two screws . adjacent to the air intake aperture. 33. Lift the top cover off whilst feeding the blower motor wiring and air control flap rod through their respective apertures, thus exposing the blower motor, heater matrix and air conditioning evaporator matrix.

Expansion valve removal 43. Support the suction pipe union with suitable spanners and release. 44. Remove the bleed pipe retaining nut from the suction pipe. 45. Remove the spring clip retaining the expansion valve sensor pipe to the main suction pipe which now rcleases the expansion valve and high pressure pipe. Place valve on bench and unscrew the high pressure pipe from the expansion valve. 46. Seal and cap all apertures; discard all 0rings which are renewed on assembly. Refitting 47. Reverse procedures 46 to 11 noting that all threads, unions, 0 rings are coated with rcfrigerant oil prior to fitting.

NOTE: Depending upon which unit has been refitted reverse the appropriate procedures: Heater Matrix or Blower Motor 5 to 3 Evaporator Matrix or Expansion Valve 10 to 6 and then charge the air conditioning system as previously described with Refrigerant 12.

Blower motor unit removal only 34. Remove the screws rctaining the motor unit to thc casing. 35. Release the three bracket retaining screws and withdraw motor and impeller. 36. Detach the star washer, spring clip and impeller. 37. Remove the two nuts from the motor shroud and lift clear.

RESISTOR BLOCK
Removal
1. Stop the engine and secure the bonnet in an open position. 2. Detach the blower motor wiring connector. 3. Remove the self tapping screw and lift the resistor block out.

. ,.

HeatedEvaporator matrices removal only 38. Lift the support ptate and insulation pad from the matrix. 39. From the bottom of the casing, remove the three screws adjacent to the dump valve outlet, in addition to the screws next to the heater pipes. 40. Lift the evaporator and heater matrices together with the supporting frame containing the air direction flap clear of the casing. 41. Detach the evaporator matrix by releasing the four screws, two at both ends of the support bracket. 42. Detach the heater matrix by removing the selftapping screw.

Refitting
4. Reverse procedures 3 to 1. 23

I82I

AIR CONDITIONING - R.H. STEERING

EVAPORATOR BLOWER MOTOR models Remova 1

- RH

Steering

Evaporator remove and refit -R.H. steering models For removal of the blower motor only, see section Evaporator Blower Motor. NOTE: It is only required to evacuate the air conditioning system when removing the evaporator matrix or changing the expansion valve. RemovaI

1. Open and secure the bonnet. 2. Release the plastic tie retaining the carburetter breather pipe to the right hand air intake elbow. 3. Remove the pulsair pipe connected to the air intake elbow. 4. Remove the right hand air intake elbow. 5 . Disconnect the clip and blower motor wiring. 6. Release the blower motor cover fixings and separate the casing slightly to allow the earth and Lucar connectors to be released.

1. Place the vehicle in a ventilated area away from open flames and heat sources. 2. Stop the engine and secure the bonnet in an open position. 3. Disconnect the battery. 4. Unscrew the radiator drain-plug and partially drain the radiator. 5 . Remove the air-cleaner. 6. Remove the caps from the compressor service valves.

Heater matrix only

7. Fully close (turn clockwise) the high pressure valve. 8. Fully open (turn anti-clockwise) the lalw pressure valve. 9. Slowly disconnect the low prcssurc pipe from the compressor rotor lock adaptor plate.
7. Remove the cover ensuring that a mark is made on the casing to indicate the correct positioning of the blower motor when refitting. 8. Release the five self-tapping screws and withdraw the blower motor and impeller. It may be necessary to move the low pressure air conditioning pipe aside to provide sufficient clearance.

9. Remove the centre nut on the impeller and carefully ease the impeller from the blower motor shaft.
Refitting

10. Reverse procedures 9 to 1 ensuring that all seals are replaced. 24

10. Remove the plastic 0 ring from the rotor lock seal. Cap and seal both unions to prevent dirt or moisture entering the system. . . 11 11. Release the p:zstic :is ~ ~ ~ ~ i !CW Pg ~ S S the f i ~ pipe to the upper engine bracket. 12. Remove the two plastic ties, securing the insulation cover on the high pressure pipe and remove the cover. 13. Whilst supporting both unions with suitable spanners, unscrew the high pressure air conditioning pipe from the evaporator.

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6, .

AIR CONDITIONING -R . H . STEERING

L%+
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Evaporator matrix and expansion valve only 14. Evacuate the air conditioning system as previously described. 15. Open (turn anti-clockwise) the compressor service valves and disconnect the gauge set. Cap all pipes and gauge connections to prevent dirt or moisture entering the system. 16. Remove the insulating cover on the low pressure pipe. 17. Whilst supporting both unions with suitable spanners, unscrew the low pressure air conditioning pipe from the evaporator. 18. Cap both ends to prevent dirt or moisture entering the system. 19. Remove the two plastic ties, securing the insulation cover on the high pressure pipe and remove the cover. 20. Whilst supporting both unions with suitable spanners, unscrew the high pressure air conditioning pipe from the evaporator.
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I

Evaporator unit 21. Remove the self tapping screw securing the air control flap solenoid. 22. Disconnect the two Ronco thermostat wires. 23. Disconnect the two heater hoses from the side of the evaporator unit. 24. Remove the vacuum pipe from the water valve switch. 25. Remove the clip and cable connection from the evaporator air flap rod. Use a new clip o n reassem bly. 26. Disconnect the blower motor wiring connections.

27. Remove the screw retaining the blower motor wiring tot he blower motor housing. 28. Remove the two bolts securing the blower motor resistor block to the engine compartment. 29. Remove the bolt securing the front support brackct to the blower motor housing. 30. From inside the vehicle rcmove the front passenger carpet and five self tapping screws which retain the toe-box cover. 31. Release the four bottom mounting bracket bolts, ensuring that the spacing washers from the two innermost bolts are retrieved from the engine bulkhead side. 32. From inside the engine compartment remove the two 13 mm upper evaporator mounting bracket bolts fitted to the engine bulkhead. 33. Lift the evaporator clear of the vehicle and place on a bench with the blower motor cover facing up. 34. Turn the evaporator unit around and remove thc fixings retaining the blower motor housing duct. 35. Remove the Ranco thermostat from the top of the unit. 36. Remove the seven self-tapping screws securing thc top and bottom halvcs of the unit togethcr. 37. Remove the eight screws from the right hand side of the unit. 38. Peel back t h e sponge pad on the outlet duct to expose the last retaining screw. Remove the screw. 39. Remove the two screws on the top of the unit. 40. Remove the joint sealant around the seam and separate the two halves of the evaporator cover assembly . 41. Remove the heater matrix from thc evaporator casing.

25

I82I

A IR CONDITIONING -R . H . STEERING

Evaporator matrix and Expansion valve only 42. Release the screws attached to the blower motor retaining plate and remove the plate. 43. Remove the blower motor inner housing. 44. Remove the bleed-pipe retaining nut from the low pressure pipe. 45. Remove the spring clip retaining the expansion valve sensor pipe to the low pressure pipe and remove the expansion valve and high pressure pipe. 46. Unscrew the high pressure pipe from the expansion valve. 47. Seal and cap all pipes and connections to prevent dirt or moisture entering the system. Discard all 0 rings, which are renewed on refitting. 48. Release the two nuts adjacent to the dump valve. 49. Remove the two evaporator mounting screws from each side of the casing. 50. Release the two uppcr evaporator mounting bracket screws and pull the bracket away from the evaporator. 51. Lift the evaporator matrix from the casing with thc two side plates and place on a bench. Refitting 52. Reverse procedures 51 to 21, ensuring that all threads, unions and 0 rings are coated with refrigerant oil prior to fitting. Discard all old 0 rings and renew on refitting. When reversing procedure 31, ensurc that the spacing washers are fitted to the two innermost bolts. NOTE: Depending upon which component has been removed, reverse the appropriate procedure as follows: Evaporator matrix and expansion valve 20 to 2 Heater matrix 13 to 2.

26

ELECTRICAL EQUIPMENT
ELECTRICAL PRECAUTIONS The following guidelines are intended to ensure the safety of the operator whilst preventing damage to electrical and any electronic components fitted to the vehicle. Before commencing any test procedure on a vehicle ensure that the test equipment is working correctly and any harness or connectors are in good condition, this particularly applies to mains leads and plugs. WARNING: Before commencing work on an ignition system, all high tension terminals, adaptors and diagnostic equipment for testing should be inspected to ensure that they are adequately insulated and shielded to prevent accidental personal contacts and minimize the risk of shock. Wearers of surgically implanted pacemaker devices should not be in close proximity to ignition circuits or diagnostic equipment. Polarity Never rcversc connect the vehicle battery and always observe the correct polarity when connecting test equipment. High voltage circuits Whenever disconnecting live high tension circuits always use insulated pliers and never allow the open end of a high tension lead to come into contact with other components particularly electronic control units. Exercise caution when measuring the voltage o n the coil terminals while the engine is running, since, high voltage spikes can occur on these terminals. Connectors and harness Always ensure that thesc items are dry and oil free before disconnecting and connecting test equipment. Never forcc connectors apart either by using tools or by pulling o n the wiring harness. Always ensure locking tabs are disengaged before removal and note orientation to enable correct reconnection. Ensure that any protective covers and substances are replaced if disturbed. Having confirmed a component to be faulty switch-off the ignition and disconnect the battery. Rcmove the component and support the disconnected TEST EQUIPMENT

86
L

harness. When replacing the component keep oily hands away from electrical connection areas and push connectors home until any locking tabs fully engage. Battery disconnecting
,

Before disconnecting the battery, switch off all electrical equipment. Battery charging Recharge the battery out of the vehicle and keep the top well ventilated. While being charged or discharged, and for approximately fifteen minutes afterwards, batteries emit hydrogen gas which is flammable. Always ensure any battery charging area is well ventilated and that every precaution is taken to avoid naked flames and sparks. GENERAL PRECAUTIONS Switch-off ignition prior to making any connection or disconnection in the system as clcctrical surge caused by disconnecting live connections can damage electronic componcnts. Ensure hands and work surfaces are clcan and frcc of grease, swarf, etc. as grease collects dirt which can cause tracking or high-resistance contacts. When handling printed circuit boards, treat them as you would a hi-fi record -hold by thc edges only. Prior to commencing a test, and periodically during a test, touch a good earth, for instance, a cigar lighter socket, to discharge body static as some clcctronic components are vulnerable to static electricity.

A range of Fast Check testers is available to provide a means of fast effective diagnosis of faults in electronic systems currently fitted to Land Rover and Range Rover vehicles. It is essential that operators familiarise themselves with t h e component> of the system to be checked and the instruction for the relevant fast check test before commencing diagnosis.

ELECTRICAL EQUIPMENT- V8 ENGINE DISTRIBUTOR

OVERHAUL V8 ENGINE DISTRIBUTOR 15. Fit the dwell angle adjustment screw and spring. 16. Fit the capacitor. 17. Fit the contact breaker set ensuring that the small post protruding from below the contact set locates through the hole in the cover plate into the hole in the end of the vacuum unit actuating lever. Secure with the screw, plain and spring washers. 18. Assemble the contact breaker spring insulating bushes and electrical leads, as illustrated in thc following sequence: a) lower bush b) spring c) low tension lead d) capacitor lead e) top bush f) and secure with the anchor spring nut. 19. Apply a few drops of engine oil to the distributor cam lubrication pad.

DISMANTLE
1. Unclip and remove the distributor cap. 2. Withdraw the rotor arm. 3 . Remove the contact breaker spring anchor nut and lift off: a) the top-half of insulation bush b) t h e low tension lead (Black) c) the capacitor lead (Orange). 4. Remove the contact breaker retaining screw, plain and spring washer and remove contact set assembly . 5 . Remove the complete insulation bush. 6. Remove the capacitor. 7. Remove the dwell-angle adjuster screw and spring. 8. Remove thc two screws and withdraw the vacuum unit and rubber joint washer. 9. Remove the three screws and lift off the centrifugal advance cover-plate with the cover plate earth lead. 10. - Punch out the drive pinion roll-pin and remove the -, drive pinion and tab washer.

e
INSPECTION
11. Examine the parts for wear and replace as necessary. Renew the capacitor and contact set. Examine the distributor cap for cracks and tracking. Renew the cap if the electrodes are worn and burned. If the cap is serviceable fit a new H.T. pick-up brush and spring. Renew the rotor arm if cracked and if the metal contact is burnt and worn. Check the low tension lead for continuity and rcnew if faulty. Check the vacuum unit diaphragm by withdrawing the air and placing a finger over the air pipe to determine if the vacuum is being held. Renew the unit if unsatisfactory.
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ASSEMBLE
When assembling, smear the centrifugal cover-plate and vacuum lever with Chevron SR1 grease or equivalent. 12. Fit t h e tab washer and drive pinion and secure with a new roll pin. --. Fit the cefitrjfqz! a&..ncP, colJer-p!atP,2nd Secure l? with the three screws noting that one screw is used to retain the centrifugal advance cover plate earth lead. 14. Fit the vacuum unit and rubber joint washer and ensure that the operating lever is inserted between the two plates which make up the centrifugal cover plate assembly. 2

20. Using a feeler gauge, and the dwell angle adjuster, set the contact breaker points to a nominal clearance of 0,35 to 0,40 mm (0.014 to 0.016 in). Once the distribute: is fitted te the engine the dwell angle must be adjusted to 26" to 28" using special tuning equipment. 21. Fit the rotor arm. 22. Fit the distributor cap ensuring that the H.T. pick-up brush moves freely in its location. 23. When fitting the distributor to the engine insert a new '0'ring seal into the body groove.

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ELECTRICAL EQUIPMENT-V8 ENGINE DISTRIBUTOR

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KEY TO DISTRIBUTOR COMPONENTS 1. Distributor cap 2. Rotorarm 3. Contact breakcr assembly 4. Capacitor and retaining screw 5. Dwell-angle adjuster screw and spring 6 . Vacuum unit and retaining screws 7. Vacuum unit joint washer 8. Centrifugal advance cover plate and retaining scrcws

ST1133M

12. 13. 14. 15.

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10.

Thrust washer Contact breaker L.T. lead and grommet Distributor cam Distributor drive dog 'vacuum unit actuating iever

86

ELECTRICAL EQUIPMENT -FOUR CYLINDER DISTRIBUTOR

16. Examine the advance mechanism of the cam, check the shaft for excessive side play. If any of these parts arc damaged or worn renew the complcte distributor. 17. Examine all other components for damage or excessive wear and renew where necessary. 18. Check the distributor cover for signs of tracking or cracks and check that t h e pick-up brush moves freely in its holder. 19. Check the rotor arm for damage, electrode security, burning and tracking.
continued

OVERHAUL DUCELLIER DISTRIBUTOR - four cylinder engine DISMANTLE Remove the distributor from the engine. Remove the distributor cap. Remove the rotor arm. Remove the dust cover. Remove the felt pad from the top of the rotor. Remove the two screws retaining the condenser and vacuum unit and remove the condenser lead from the connector block. 7. Remove the retaining clip from the eccentric D post. 8. Mark the position of the serrated cam in relation to the spring seat of the vacuum operating link. 1. 2. 3. 4. 5. 6.

ST1279M

9. Disengage the vacuum operating link and serratcd cam from the eccentric D post and remove the vacuum unit. 10. Remove the retaining screw and withdraw the fixed contact plate. 11. Remove the retaining clip and insulation washer. 12. Release the connector block from the distributor body. 13. Lift out the moving contact complete with connector block and leads. 14. Mark the relationship of the base plate to the body and remove the retaining screw. Whilst holding the pressure pad clear of the rotor, withdraw the base plate. 15. Remove the moving contact post-plate.
INSPECTION NOTE: The distributor drive dog is loosely retained on the drive shaft, the float allows for any misalignment.
4

ELECTRICAL EQUTPMENT-FOUR CYLINDER DTSTRIBUTOR

REASSEMBLE OVERHAUL LUCAS 45D4 DISTRIBUTOR cylinder engine Dismantling

186I
- Four

20. Using Rctinax A or equivalent grease lubricate the centrifugal weight pivot posts and lightly smear the cam pressure pad and contact pivot post. 21. Fit the pressure pad and spring to the base plate. 22. Fit the base plate to the body, lining up the marks, and secure with the retaining screw and clip on the opposite side to the vacuum unit. 23. Smear a little grease on the post and fit the moving contact post-plate to t h e base plate. 24. Offer up the vacuum unit to the body and fit the operating link and serrated cam to the D post. Ensure that the identification marks line up - see instruction 8. Secure the assembly with the spring clip. 25 Secure the vacuum unit and condenser to the body with the remaining screw and clip. 26. Fit the fixed contact and loosely retain with the screw. 27. Fit the moving contact ensuring that the leaf spring locates in the nylon guide. 28. Fit the connector block to the body. 29. Fit the insulation washer and retain assembly with the spring clip. 30. Fit condenser lead to connector block. 31. Place the felt pad in the top of the rotor and add a few drops of oil. 32. Smear a small quantity of grease on the rotor cam. 33. Adjust the contact point gap to a datum setting of 0,43 mm (0.017 in) with a feeler gauge by turning the rotor spindle until a cam fully opens the points. Move the fixed contact plate to obtain the required gap and tighten the retaining screw. 34. Fit the distributor to the engine. 35. Fit the dust cover. 36. Fit the rotor arm and distributor cap. 37. Connect the H.T. leads to the appropriate spark plugs.
I

I . Remove the rotor arm. 2. Extract the felt pad, if fitted, from the cam. 3 . Removc the two vacuum unit retaining screws, tilt .the unit to disengage the operating arm and remove the vacuum unit. 4. Push the low tension lead and grommet into the inside of the body. 5. Remove the securing screws and lift out the base plate assembly. 6. Drive out the parallel pin retaining the drive dog. 7. Remove the drive dog and thrust washer. 8. Remove the shaft complete with automatic advance mechanism and steel washer. 9. Push the moving contact spring inwards and detach the low tension connector from the spring loop. 10. Removc the screw to release the earth lead and capacitor. 11. Remove the sccuring screw and lift off the contact set.
Inspection 12. Do not dismantle the advance mechanism beyond removing the control springs. If any of the moving parts or the cam are worn o r damagcd, renew the complete shaft assembly. 13. Check the fit of the shaft in its bearing: if the bcaring allows cxcessive side play, renew the completc distributor. 14. Check the base plate assembly; if the spring between the plates is damaged or if the plates do not move freely, renew the assembly. 15. Check the distributor cap for signs of tracking or cracks and check that the pick-up brush moves freely in its holder. 16. Chcck the rotor arm for damage, electrode security, and burning or tracking. Keassem bling 17. Reverse the procedure in 1 to 11, noting thc following instructions. 18. Lubricate t h e contact pivot post with Retinax A or equivalent grease. 19. Ensure that the steel washer is fitted on the shaft and lubricate the shaft with Rocol MP (Molypad). 20. Fit the thrust washer with its raised pips towards the drive dog.
continued

1 4

ELECTRICAL EQUIPMENT -FOUR CYLINDER DISTRIBUTOR

ST1832M

21. Fit the drive dog so that the driving tongues are parallel with the rotor arm electrode and to the left of its centre line when the rotor arm points upwards as shown.

ST

22. If a new shaft is fitted it must be drilled through the drill. hole in the drive dog using a 4.76 mm (A) 23. During drilling, push the shaft from the cam end, pressing the drive dog and washer against the body shank. 24. Secure the pin in the drive dog by ring-punching the holes. If the shaft is new, tap the drive end to flatten the washer pips and ensure the correct end-float. 25. Set the contact points gap.

g- '? 2 1

ELECTRONIC IGNITION -V8 ENGINE

186

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ELECTRONIC DISTRIBUTOR

IGNITION

WITH

35DMS

The Lucas model 35DM8 distributor has a conventional advancehetard vacuum unit and centrifugal automatic advance mechanism. A pick-up module, in conjunction with a rotating timing reluctor inside the distributor body, generates timing signals. These are applied to an electronic ignition amplifier unit fitted under the ignition coil mounted on top of the left front wing valance.

Key to illustration
I.

I: Cap 2. HT Brush and spring 3 . Rotorarm 4. Insulation cover (Flash shield) 5. Pick-up and base plate assembly 6. Vacuum unit 7. 0 ring oil seal

RR458M

16 ELECTRONIC IGNITION -V8 ENGINE 81

DISTRIBUTOR -ELECTRONIC IGNITION V8 ENGINES 35DM8 Remove and refit Removing

1. 2. 3. 4.

Disconnect battery. Disconnect vacuum pipe(s). Remove distributor cap. Disconnect low tension lead from coil. 5. Mark distributor body in relation to centre line of rotor arm.

RR616M

9. If engine has not been turned whilst distributor has been removed, proceed as follows (items 10 to 17). 10. Fit new '0'ring seal to distributor housing. 11. Turn distributor drive until centre line of rotor arm is 30" anti-clockwise from mark made on top edge of distributor body. 12. Fit distributor in accordance with alignment markings.
NOTE: It may be necessary to align oil pump drive shaft to enable distributor drive shaft to engage in slot.

6. Add alignment marks to distributor and front

cover.

NOTE: Marking distributor enables refitting in exact original position, but if engine is turned while distributor is removed, complete ignition timing procedure must be followed.

7. Release the distributor.

Refitting

distributor

clamp

and

remove

NOTE: If a new distributor is being fitted, mark body in same reiative position as distributor removed. 8. Leads for distributor cap should be connected as illustrated. Figures 1 to 8 inclusive indicate plug lead numbers. RH - Right hand side of engine, when viewed from the rear. LH Left hand side of engine, when viewed from the rear. 8

13. Fit clamp and bolt. Secure distributor in exact original position. 14. Connect vacuum pipe to distributor and low tension lead to coil. 15. Fit distributor cap. 16. Reconnect battery. 17. Using suitable electronic equipment, set ignition timing as follows. 18. If, with distributor removed, engine has been turned it will be necessary t o carry out the follwing procedure. 19. Sct engine - No. 1 piston to static ignition timing figure (see section 05) on compression stroke. 20. T u r n distributor drive until rotor arm is approximately 30" anti-clockwise from number one sparking plug lead position o n cap. 3-1. Fit distributor to engine. 22. Check that centre line of rotor arm is now in line with number one sparking plug lead o n cap. Reposition distributor if necessary. 23. If distributor does not seat correctly in fron cover, oil pump drive is not engaged. Engage by lightly pressing down distributor while turning engine. 24. Fit clamp and bolt leaving both loose at this stage. 25. Set the timing statically to within 2"-3"of T.D.C. 26. Connect vacuum pipe(s) to distributor. 27. Fit low tension lead to coil. 28. Fit distributor cap. 29. Reconnect battery. 30. Using suitable electronic equipment set thc ignition timing.

ELECTRONIC IGNITION -V8 ENGINE

186I

1. It is essential that the following procedures are adhcrcd to. Inaccurate timing can lead to scrious engine damage and additionally create failurc to comply with the emission regulations applying to the country of destination. If the engine is being checkcd in the vehicle and is fitted with an air conditioning unit the compressor must be isolated. 2. On initial engine build, or if the distributor has been disturbed for any reason, the ignition timing must be set statically to within 2"-3" of T.D.C. (This sequence is to give only an approximation in order that the engine may be started) ON NO ACCOUNT MUST THE ENGINE BE STARTED BEFORE THIS OPERATION IS CARRIED OUT. Refer to 'Engine Tuning Data' for ignition timing specification.
%

LUCAS CONSTANT ENERGY IGNITION SYSTEM 35DMS PRELIMINARY CHECKS

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 H T leads arc correctly positioned and not shorting to earth against any engine components. The wiring harness and individual cables should be firmly fastencd to prevent chafing.

PICK-UP MODULE AIR GAP SETTINGS Air gap settings vary according to vehicle application. NOTE: The gap is set initially at the factory and will only require adjusting if tampered with o r when the pick-up module is replaced.

Equipment required Calibrated Tachomctcr Stroboscopic lamp

Test Notes

3 . Couple stroboscopic timing lamp and tachometer to engine following the manufacturcrs instructions. 4. Disconnect the vacuum pipes from t h c distributor. 5 . Start engine; with no load and not exceeding 3,000 rpm, run engine until normal opcrating temperature is reached. (Thermostat open). Check that the normal idling speed falls within the tolerance specificd in table. 6. Idle speed for timing purposes must not excccd 750 rpm, and this speed should be achieved by removing a breather hose, NOT BY ADJUSTING CARBURETTER IDLE SETTING SCREWS. 7 . With the distributor clamping bolt slackened, turn distributor until the timing flash coincides with t h e timing pointer and the correct timing mark on the rim of the torsional vibration dampcr as shown in the table. 8. Retighten the distributor clamping bolt securely. Rccheck timing in the event that retightening has disturbed the distributor position. 9. Refit vacuum pipes. 10. Disconnect stroboscopic timing lamp and tachometer from engine.

(i) The ignition must be switched on for all chccks. (ii) Key to symbols used in charts for Tests 2. Correct High Low Reading Rcading Reading (iii) Use feeler gauges manufactu.red from a nonmagnetic material when setting air gaps.

TEST 1: Check HT Sparking Remove coiVdistributor H T lead from distributor cover and hold approximately 6 mm (0.25 in) 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.

Test 1
Crank engine

RR460M

li z
TEST 2:

ELECTRONIC IGNITION -FAULT DIAGNOSIS

Test 2

Amplifier Static Checks 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.

NOTE: Only move the voltmeter positive lead during tests 2 , 3 and 4.
(b) Compare voltages obtained with the specified values listed below:EXPECTED READINGS 1 More than 11.5 volts 2 1 volt max below volts at point 1 in test circuit 3 1volt max below volts at point 1in test circuit 4 0 volt -0.1volt (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.

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TEST 3:
Check Amplifier Switching

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SUSPECT Discharged battery Ign. switch and/or wiring Coil o r amplifier Amplifier earth

TEST 4: Pick-up Coil Resistance. Applications with Separate Amplifier 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. Change the amplifier if ohmmeter reading is correct. 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.

Disconnect the High Tension lead between the coil and distributor. 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. If there is no increase in voltage during cranking proceed to Test 4.
Test 3

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-5 >

Test 4

To ign switch

RR462M

RR463M

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ELECTRONIC IGNITION -FAULT DIAGNOSIS

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TEST5: Check HT Sparking Remove existing coil/distributor H T lead and fit test H T lead to coil chimney. Hold free end about 6 mm (0.25 in) from the engine block and crank the engine. H T sparking good, repeat test with original HT lead, if then no sparking, change HT lead. If sparking is good but engine will not start, proceed to Test 6. If no sparking, replace coil. If engine will not start carry out Test 6.
Test 5
Crank

TEST 7: Visual and HT Cable Checks Should be: Clean, dry, no tracking marks Clean, dry, no tracking marks Must not be cracked chafed or perished 4. HT Cable Continuity Must not be open circuit 5 . Sparking Plugs Clean, dry, and set to correct gapNOTE: 1. Reluctor Must not foul pick-up or leads 2. RotorandFlash Must not be cracked or show Shield signs of tracking marks. Examine: 1. Distributor Cover 2. CoilTop 3. H T Cable Insulation

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TEST 6: Check Rotor Arm Remove distributor cover. Disconnect coil H T lead from cover and hold about 3 mm (0.13 in) 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. HT sparking, replace rotor arm. If engine will not start carry out Test 7.
Test 6
Crank engine

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11

I86 I

ELECTRONIC IGNITION -V8 ENGINE

Re-Assembly 14. This is mainly a reversal of the dismantling procedure, noting the following points: Lubrication Apply clean engine oil: (a) 3 drops to felt pad reservoir in rotor shaft. Apply Chevron SH1 (or equivalent) grease. (b) Auto advance mechanism (c) Pick-up plate centrc bearing (d) Pre tilt spring and its rubbing area (pick-up and base plate assy) (e) Vacuum unit connecting peg (pick-up and base assy) and (f) the connecting peg hole in vacuum unit connecting rod. Apply Rocal MHT (or equivalent) grease. (8) Vacuum unit connecting rod seal (located in vacuum unit where connecting rod protrudes) NOTE: Applicable only to double acting vacuum units. Fitting Pick-up and Base Plate Assembly

OVERHAUL DISTRIBUTOR - LUCAS 35DM8 Distributor Cap

1. Unclip and remove cap. 2. Renew cap if known to be faulty. 3 . Clean with a nap-free cloth.
Rotor Arm 4. Pull rotor arm from keyed shaft. 5 . Renew rotor arm if known to be faulty. Insulation Cover (Flash shield)

6. Remove cover, secured by 3 screws. 7. Renew cover if known to be faulty.

Vacuum Unit

8. Remove 2 screws from vacuum unit securing bracket, discngage vacuum unit connecting rod from pick-up base plate connecting peg, and withdraw vacuum unit from distributor body.
Pick-up and Base Plate Assembly

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9. Use circlip pliers to remove the circlip retaining the reluctor on rotor shaft. 10. Remove the flat washer and then the '0' ring recessed in the top of t h e reluctor. 11. Insert the blade of a small screwdriver bcneath the reluctor and prise it partially along the shaft, sufficient to enable it to be gripped between fingers and withdrawn from t h e shaft.
NOTE: Coupling ring fitted beneath reluctor. 12. Remove pick-up and base plate assembly, secured by 3 support pillars. NOTE: Do not disturb the 2 barrel nuts securing the pick-up module, otherwise the air gap will need re-adjustment.
13. Renew pick-up and base plate assembly if module is known to be faulty, otherwise check pick-up winding resistance (2k-5k ohms).

15. Pick up leads must be prevented from fouling the rotating reluctor. Both leads should be located in plastic carrier as illustrated. Check during reassembly.

TECHNICAL DATA Firing angles ..................................................... Appiicaiivn ....................................................... Pick up air gap adjustment (Pick up limbheluctor tooth) ................................. Pick up winding resistance .................................... 0"-45"-90" etc. ? 1"
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0.20 mm - 0.35 mm (0.008 in - 0.014 in)

2k - 5k ohms

12

ELECTRONIC IGNITION -V8 ENGINE

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I86 I

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Refitting Reluctor

16. Slide reluctor as far as it will go on rotor shaft, then rotate reluctor until it engages with the coupling ring beneath the pick up base plate. The distributor shaft, coupling ring and reluctor are 'keyed' and rotate together.
Pick Up Air Gap Adjustment

ELECTRONIC IGNITION Distributor

- with

Lucas 35DLMS

The Lucas 35DLM8 distributor has a conventional advancehetard unit and centrifugal automatic advance mechanism. A pick-up module, in conjunction with a rotating timing reluctor inside the distributor body, generates timing signals. These are applied to an electronic ignition amplifier module mounted on the side of the distributor body. NOTE: The pick-up air gap is factory set. Do not adjust the gap unless the pick-up is being changed or the base plate has been moved. Use a non-ferrous feeler gauge to set the air gap.

17. The air gap between the pick up limb and reluctor teeth must be set within the specified limits, using a non-ferrous feeler gauge.
NOTE 1: When the original pick up and base plate assembly has been refitted the air gap should not normally require resetting as it is pre-set at the factory. When renewing the assembly the air gap will require adjusting to within the gpecified limits. See technical data.

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AMPLIFIER Remove and Refit Removing

DISTRIBUTOR -35DLM8 Remove and refit Removing Disconnect battery. 2. Disconnect vacuum pipe(s). distributorcap. 3. 4. Disconnect low tension lead from coil. 5 . Mark distributor body in relation to centre line of rotor arm

18. Disconnect the battery. 19. Disconnect the electrical lcads from the amplifier and coil. 20. Remove t h e two retaining bolts with washers securing the coil to the amplifier. 21. Remove the two bolts securine thc amdifier to the " valance.
Refitting
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22. Reverse the removal procedure, ensuring that all electrical leads are correctly reconnected. NOTE: The amplifier is not serviceable, in the event of a fault a new amplifier must be fitted.

6. Add alignment marks to distributor and front cover.

13

ELECTRICAL
13. Fit clamp and bolt. Secure distributor in exact orginal position. 14. Connect vacuum pipe to distributor and low tension lead to coil. 15. Fit distributor cap. 16. Reconnect battery. 17. Using suitable electronic equipment, set the ignition timing, See IGNITION TIMING Adjust. 18. If, with distributor removed, engine has been turned it will be necessary to carry out the following procedure. 19. Set engine - No. 1 piston to static ignition timing figure (see data section) on compression stroke. 20. Turn distributor drive until rotor arm is approximately 30" anti-clockwise from number one sparking plug lead position on cap. 21. Fit distributor to engine. 22. Check that centre line of rotor arm is now in line with number one sparking plug lead on cap. Reposition distributor if necessary. 23. If distributor does not seat correctly in front cover, oil pump drive is not engaged. Engage by lightly pressing down distributor while turning engine. 24. Fit clamp and bolt leaving both loose at this stage. 25. Set the ignition timing statically to within 2"-3" of T.D.C. 26. Connect the vacuum pipe to the distributor. 27. Fit low tension lead to coil. 28. Fit distributor cap. 29. Reconnect the battery. 30. Using suitable electronic equipment set the ignition timing, See IGNITION TIMING - Adjust.
DISTRIBUTOR-LUCAS35DLM8 Overhaul DISTRIBUTOR COVER
A

NOTE: Marking distributor enables refitting in exact original position, but if engine is turned while distributor is removed, complete ignition timing procedure must be followed.

7. Release the distributor clamp and remove the distributor.

Refitting NOTE: If a new distributor is being fitted, mark body in same relative position as distributor removed.

8. Leads for distributor cap should be connected as illustrated. Figures 1to 8 inclusive indicate plug lead numbers. R H - Right-hand side of engine, when viewed from the rear. L H - Left-hand side of engine, when viewed from the rear.

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1. Unclip and remove the cover. 2. Renew the cover if known to be faulty. 3. Clean the cover and HT brush with a nap free cloth. ROTOR ARM
4. Pull rotor arm from keyed shaft. 5. Renew rotor arm if known to be faulty.

9. If engine has not been turned whilst distributor has been removed, proceed as follows (items 10 to 17). 10. Fit new '0'ring seal to distributor housing. 11. Turn distributor drive until centre line of rotor arm is 30' anti-clockwise from mark made on top edge of distributor body. 12. Fit distributor in accordance with alignment
markings. NOTE: it may be necessary to align oil pump drive shaft to enable distributor drive shaft to engage in slot.
14

INSULATION COVER (Flash shield) 6. Remove cover, secured by three screws. 7. Renew cover if known to be faulty. VACUUM UNIT

8. Remove two screws from vacuum unit securing

bracket, disengage vacuum unit connecting rod from pick-up base plate connecting peg, and withdraw vacuum unit from distributor body.

ELECTRICAL
AMPLIFIER MODULE

86

FITTING PICK-UP AND BASE PLATE ASSEMBLY

9. Remove two screws and withdraw the module. 10. Remove the gasket. 11. Remove two screws securing the cast heatsink and remove the heatsink. WARNING: The amplifier contains Beryllia. Do not open or crush.
PICK-UP AND BASE PLATE ASSEMBLY 12. Use circlip pliers to remove the circlip retaining the reluctor on rotor shaft. 13. Remove the flat washer and then the 0ring recessed in the top of the reluctor. 14. Gently withdraw the reluctor from the shaft, taking care not to damage the teeth. NOTE: Coupling ring fitted beneath reluctor.

18. Pick-up leads must be prevented from fouling the rotating reluctor. Both leads should be located in plastic carrier as illustrated. Check during reassembly.

15 Remove three support pillars and cable grommet. Lift out the pick-up and base plate assembly.
NOTE: Do not disturb the two barrel nuts securing the pick-up module, otherwise the air gap will need re-adjustment.

REFITTING RELUCTOR

19. Slidc reluctor as far as it will go on rotor shaft, then rotatc reluctor until it engages with the coupling ring beneath t h e pick-up base plate. The distributor shaft, coupling ring and reluctor are kcycd and rotate together. Fit the 0ring, flat washcr and retaining circlip.
PICK-UP AIR GAP ADJUSTMENT
20. The air gap between the pick-up limb and reluctor teeth must be sct within the spccified limits, using ;I non-ferrous feeler gauge. 21. If adjustmcnt is necessary, slacken the two barrel nuts to set the air gap. See Engine Tuning Data.

16. Renew pick-up and base plate assembly if module is known to be faulty, otherwise check pick-up winding resistance (2k-5k ohm).

RE-ASSEMBLY

17. This is mainly a reversal of the dismantling procedure, noting the following points:
LUBRICATION Apply clean engine oil: a. Threc drops to felt pad reservoir in rotor shaft. Apply Chevron SR1 (or equivalent) grease. b. Auto advance mechanism. c. Pick-up plate centre bearing. d. Pre tilt spring and its rubbing area (pick-up and base plate assy). e. Vacuum unit connecting peg (pick-up and base plate assy) and f. the connecting peg hole in vacuum unit connecting rod.

NOTE: When the originai pick-up and base plate assembly has been refitted the air gap should be checked, and sdjusted if?--------. I cLcn3ai y When renewing the assembly the air gap will require adjusting to within the specified limits.

15

ELECTRICAL

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Service Parts 1. Cover 2. HT brush & spring 3. Rotor arm 4. Insul cover 5 . Pick-up module and base platc asscmbly 6. Vacuum unit 7. Amplifier module 8. 0 - r i n g o i l scal 9 Gasket
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ELECTRICAL
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22. Before fitting the module, apply MS4 Silicone grease or equivalent heat - conducting compound to the amplifier module backplate, the seating face on distributor body and both faces of the heatsink casting.
IGNITION TIMING Adjust

LUCAS CONSTANT ENERGY IGNITION SYSTEM 35DLM8 PRELIMINARY CHECKS

Inspect battcry cables and conncctions to ensure they are clcan 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 HI' leads are corrcctly positioncd and not shorting to earth against any cnginc components. The wiring harness and individual cables should be firmly fastened to prevent chafing.

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1. It is essential that thc following procedures are adhered to. Inaccurate timing can lead to serious engine damage and additionally crcate failure to comply with the emission regulations applying to the country of destination. If the engine is being checked in thc vehicle and is fitted with an air conditioning unit the compressor must be isolated. 2. On initial engine build, or if the distributor has been disturbed for any reason, the ignition timing must be set statically to 6" B.T.D.C. (This sequence is to give only an approximation in order that the engine may be started) ON NO ACCOUNT MUST THE ENGINE BE STARTED BEFORE THIS OPERATION IS CARRIED OUT.

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

Equipment required

Calibrated Tachometer Stroboscopic lamp 3. Couple stroboscopic timing lamp and tachometer to engine following the manufacturers instructions. 4. Disconnect thc vacuum pipes from the distributor. 5. Start engine, with no load and not exceeding 3,000 rpm, run engine until normal operating temperature is reached. (Thermostat open). Check that the normal idling speed falls within the tolerance specified in the data section. 6. Idle speed for timing purposes must not exceed 750rpm, and this speed should bc achieved by removing a breather hose NOT BY ADJUSTING IDLE SETTING SCREWS. 7. With the distributor clamping bolt slackened turn distributor until the timing flash coincides with the timing pointer and the correct timing mark on the rim of the torsional vibration damper as shown in t h e engine tuning section. 8. Retighten the distributor clamping bolt securely. Recheck timing in t h e event that retightening has disturbed the distributor position. 9. Refit vacuum pipes. 10. Disconnect stroboscopic timing lamp and tachometer from engine.

Remove coil/distributor HT lead from distributor cover and hold approximately 6 mm (0.25 in) from the engine block. Switch thc ignition 'on' and operate thc start er. If regular sparking occurs, proceed to Test 6 . If no sparkingproceed to Test 2.

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186I
TEST 2:

ELECTRICAL
TEST 3: Check Amplifier Switching

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:
EXPECTED READINGS

Connect the voltmcter between battery positive (+ ve) terminal and FIT coil negative (- ve) tcrminal: the voltmeter should register zero volts. Switch the ignition 'on' and crank the engine. Thc voltmeter reading should increase just above zero, in which case proceed with Test 5 . If there is no increase in voltage during cranking proceed to Test 4.
-

V1. V2. V3. v4.

More than 11.5 volts 1 volt max below volts at point 1 in test circuit 1 volt max below volts at point 1 in test circuit 0 volt -0.1 volt

TO DfSTRlBUTOR

CRANK

TO IGN SWITCH

TO AMPLIFIER T O STARTER

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TEST 4: Pick-up Coil Resistance.

(c) If all readings are correct proceed to Tcst 3. (d) Check incorrect reading(s) with chart to identify area of possiblc faults, i.e. faults listed under heading 'Suspect'. (e) If coil or amplifier is suspected, disconnect LT lead at coil, repeat V3. If voltage i s 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 Tcst 3.
' 1

Disconnect the pick-up leads at the harncss connector. Connect the ohmmeter lcads to t h e two pick-up lcads in the plug. The ohmmeter should registcr between 2k and 5k ohms if pick-up is satisfactory. If the ohmmcter reading is correct, check all connections between pick-up and amplificr, if satisfactory, fit new amplifier. If the engine still does not start carry out Test 5 . Change thc pick-up if ohmmeter reading is incorrect. If the engine still does not start proceed to Test 5 .

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SUSPECT Discharged battery

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ELECTRICAL
TEST 7:

186I

Coil H1' Sparking Remove existing coil/distributor H T lcad and fit test H T lead to coil tower. Using suitable insulated pliers, hold free end about 6 mm (0.25 in) from the engine block and crank t h e engine. There should be a good FIT spark. If weak or no sparking, fit new coil, rcpeat test. HT sparking good, repeat test with original H T 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.
CRANK

Visual and HT Cable Checks

Should bc: Clean, dry, no tracking marks Clean, dry, no tracking marks Must not be cracked chafed or perished 4. H T Cable Continuity Must not be open circuit 5. Sparking Plugs Clean, dry, and set to correct gap. NOTE: 1. Reluctor Must not foul pick-up or leads 2. Rotor and Flash Must not be cracked or show signs of tracking marks. Shield Examine: 1. Distributor Cover 2. CoilTop 3. H T Cable Insulation

TEST 6: Rotor Arm

Remove distributor cover. Disconnect coil HT lead from covcr and using insulatcd pliers, hold about 3 mm (0.13 in) above rotor arm electrode and crank the engine. There should be n o HT sparking bctwecn rotor and H T lead. If satisfactory carry out Test 7. If H T sparking occurs, an earth fault on the rotor arm is indicated. Fit new rotor arm. If engine will not start carry out Test 7.

R R 2267E

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19

86

ELECTRICAL EQUIPMENT- ALTERNATOR

Separating drive end bracket and rotor
15. Remove the shaft nut washers from the pulley, woodruff kcy and spacers. 16. Use a press to remove the rotor shaft from the drive end bearing. Check all components as detailed under bench testing and renew any parts that arc unsatisfactory. If necessary the slip rings and or thc slip ring end bearing on the rotor shaft can bc rcplaced. To renew t h e bearing, both slip rings must be rcmoved as follows: 17. Unsolder outer slip ring connection and gently prise the slip ring off t h e shaft. 18. Unsolder inner slip ring conncction and gently prise the slip ring off the shaft.

ALTERNATOR OVERHAUL - Lucas A115-3 and A115-45 DISMANTLE

1. Remove the alternator from the engine. 2. Remove the cover retaining screws and lift off the cover.

Removing the surge protection diode

3 . Withdraw the screw securing the diode to the slip ring end bracket. 4. Disconnect the lead from the rectifier assembly and remove the diode.
Removing the regulator (Note arrangement of the brush box connections)
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5. Disconnect the regulator leads. 6. Remove the screw securing the regulator to the brush box and withdraw the regulator. Note that this screw also secures t h e inner brush mounting plate in position.
Removing brush box assembly

Whilst carrying out the above two imtructions take care not to damage t h e insulation covering the winding leads.

ELECTRICAL TEST OF COMPONENlS

7. Remove the screw retaining the outer brush mounting plate. 8. Withdraw both brushcs. 9. Remove the two screws securing the brush box to the slip ring end bracket and lift off the brush box.
Removing the rectifier assembly
10. Securely clamp the alternator and release the stator winding cable ends from t h e rectifier by applying a

The illustrations for the following tcsts show the Components scparated from t h e altcrnator, for clarity.
Rotor field winding

hot soldering iron to the tcrminal tags of the rectifier. When the solder melts prise out the cable end. 11. Remove the two remaining screws securing the rectifier assembly to the slip ring end bracket and lift off the rectifier.
NOTE: Further dismantling of the rectifier is not required. Removing the slip ring end bracket 12. Sccurely clamp the alternator and remove t h e thrce fixing bolts. 13. Lift off the bracket. If necessary tap under each fixing bolt with a soft mallet. Removing stator assembly

19. Chcck field winding continuity and resistance simultaneously, by connecting either a batteryoperated ohmmeter (illustration A) or a 12 volt battery and moving coil ammeter (illustration B) between the slip rings. The ohmmetcr should indicate the appropriate resistance given in the data, or it should indicate a current approximate to the figure obtained by dividing the appropriate resistance of the rotor into the battery voltage.

ST!282??!

14. Note the position of the stator output leads relative to the alternator fixing lugs and then l i f t the stator from the drive end bracket.

20

ELECTRICAL EQUIPMENT -ALTERNATOR

86

10

ST 1280M

14
KEY TO ALTERNATOR 9. Slip ring end bracket 10. Stator 11. Brush box 12. Brushset 13. Fixing bolt -slip ring end bracket to drive-end bracket 14. Suppression capacitor 15. Surge protection diode

1. 2. 3. 4. 5. 6. 7. 8.

Cover Regulator Rectifier Drive-end bracket End bearing kit Rotor assembly Slip ring end bearing Slip rings

21

I86 I

ELECTRICAL EQUIPMENT -ALTERNATOR

19

12"

ST1283M

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ST1285M

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20. Check for satisfactory field winding insulation by connecting a 110 V A.C. 15-watt test lamp betwcen either of the slip rings and t h e rotor body. The lamp should not light.

Rectifier diodes

24. Test each of the nine diodes separately, as follows. Connect a 12 V battery and a 1.5 watt bulb in series with one of the diodes, one test lead being applied to the diode connecting pin and the other to the particular heat sink plate in which the diode undergoing test is soldered. Note whether lamp lights, then reverse the test lead connections. The lamp should light during one half of the test only. If any one diode test is unsatisfactory, renew the rectifier assembly.
Regulator
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Stator winding

21. Due to the very low resistance of the stator windings, a practical test to determine the presence of short-circuited turns cannot be carried out without the usc of special instruments. However, in practice inter-winding short-circuiting is usually indicated by obvious signs of burning of the insulating varnish covering the windings. If this is the case, renew the stator assembly without the need for further testing. '22. Check continuity of stator windings, by first connecting any two of the three stator winding connecting cables in scries with a 12 V batteryoperated tcst lamp, of not less than 36 watts. The test lamp should light. If not, renew the stator assembly. Providing the first part of the test is satisfactory, transfer one of the test lamp leads to t h e other (third) cable. Again the test lamp should light. If so, proceed to insulation test. 23. Check insulation of stator windings, by connecting a 110 V A.C. 15-watt test lamp between the stator laminations and any one of the three connecting cables. The lamp should not light.

25. Individual testing of the regulator can only be carried out with special test equipment and unless this is available the regulator must be proved by substitution.
ASSEMBLE
Reassembly of the alternator is a reversal of the dismantling procedure. However the following points should be observed. 26. Take care not to damage the insulation covering the winding leads when renewing the slip rings. 27. A build up of solder must not occur on t h e upper face of the inner slip ring. 28. Use resin cored solder only. 29. Pack the bearings with a suitable high melting point grease. 30. Ensure that the brushes move freely in the brush box. 31. If t h e slip rings are not renewed the existing ones must be clean and smooth. 32. Tighten fixings to the torque figures quoted.
continued

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22

ELECTRICAL EQUIPMENT-ALTERNATOR

ST1286M

TIGHTENING TORQUES
Through bolts ..................................................... Shaft nut ............................................................ Rectifier fixing bolts ............................................. Sundry screws: SRE Cover ...................................................... Brush Box ....................................................... Surge Diode .................................................... Capacitor.. ...................................................... Brush and Regulator fixing ................................. D/E Bearing Plate ............................................. Reg IND Lead ................................................ NUTS: Main output terminal.. ....................................... IND terminal nuts ........................................... 4.5 - 6.2 Nm (3.3 - 4.6 Ibf it) 27.2 - 47.5 Nm (20.0 - 35.0 Ibf ft) 3.4 - 3.96 Nm (2.5 - 2.9 Ibf ft) 1 . 7 - 2 . 2 5 (1.3- 1.7Ibfft) 3.4 - 3.96 Nm (2.5 - 2.9 Ibf ft) 3.4 - 3.96 Nm (2.5 - 2.9 Ibf ft) 3.61 - 4.74 Nm (2.7 - 3.5 Ibf ft) 1.7 - 2.25 Nm (1.3 - 1.7 Ibf ft) 4.7 - 5.7 Nm (3.5 - 4.2 Ibf ft) 1.1 - 1.36 N m (9.7 - 12.0 lbf in) 3.96 - 5.08 Nm (2.9 - 3.7 Ibf ft) 3.61 - 4.74 Nm (2.7 - 3.5 Ibf ft)

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23

86

ELECTRICAL E Q UI P ME NT - ALTERNATOR
When using rapid charge equipment to re-charge the battery, the battery must be disconnected from the vehicle.

ALTERNATOR OVERHAUL -Lucas A12745 Description

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.--

The model A127 alternator is a three phase, field sensed unit, the rotor and stator windings generate three phase alternating current (AC) which is rectified to direct current (DC). The electronic voltage regulator unit controls the alternator output voltage by high frequency switching of the rotor field circuit. It i s essential that good electrical connections are maintained at all times. Of particular importance are those in the charging circuit (including those at the battery) which should be occasionally inspected to see that they are clean and tight. In this way any significant increase in circuit resistance can be prevented.

NOTE: Alternator charging circuit - The ignition warning light is connected in series with the alternator tield circuit. Bulb failure would prevent the alternator charging, except at very high engine speed, therefore, the bulb should be checked before suspecting an alternator failure.
Precautions

Battery polarity is NEGATIVE E A R T H , which must be maintained at all times. No separate control unit is fitted; instead a voltage regulator of micro-circuit construction is mounted on the slip ring end bracket.
4, ? ? -.

Do not disconnect battery cables while the engine is running or damages to the semi-conductor devices may occur. It is also inadvisable to break o r make any connections in the alternator charging and control circuits while the engine is running.
The model 21TR electronic voltage regulator employs micro-circuit techniques resulting i n improved performance under difficult service conditions. The whole assembly is encapsulated i n silicone rubber and housed in an aluminium heat sink, ensuring complete protection against the adverse effects of temperature, dust, and moisture etc.

Battery voltage is applied to thc alternator output cable even when the ignition is switchcd off, the battery must be disconnected before commencing any work on the alternator. The battery must also be disconnected when repairs to the body structure arc being done by arc we I ci i ng .
DISMANTLE
1. Withdraw the connectors from the alternator. 2 . Re mo vc; the a I t e r n a tor . 3. Remove the nuts from the through bolts, disconnect the connectors and remove two suppression capacitors. 4. Remove three screws, disconnect one lead and withdraw the regulator and brushbox assembly. 5 . Check the brush lengths by measuring length of protrusion from moulding. If dimension A is 5mm (0.20in) o r less, change thc assembly.

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The brushbox assembly is incorporated in the regulator unit. Surge protection is incorporated in the regulator unit. The regulating voltage is set during manufacture to give the required regulating voltage range of 13.6 to 14.4 volts, and no adjustment is necessary. The only maintenance needed is the occasional check o n terminal connections and wiping with a clean dry cloth. The alternator system provides for direct connection of a charge (ignition) indicator warning light. and eliminates t h e need for a field switching relay or warning light control unit. As the warning lamp is connected i n the charging circuit, lamp failure will cause loss of charge. Lamp should be checked regularly and a spare carried.

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ELECTRICAL EQUTPMENTill*

ALTERNATOR

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ALTERNATOR -LUCAS A 127-65

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Service parts

1 . Suppression capacitors - 2 off 2. Regula t or/Brus h box assembly 3. Through bolts 4. Slip ring end (SRE) bracket 5. Stator 6. Rectifier 7. Drive end bracket (DRE)/bearing assembly 8. "noior 9. Slip ring end bearing

25

186I

ELECTRICAL EQUIPMENT -ALTERNATOR

6. Check brush spring pressure using a push type spring guage. Gauge should register 136 to 279 g ( 5 to 10 02) when brush is pressed until face is flush with housing. If reading is outside these limits, renew assembly. 7. Mark the relative positions of the end brackets and stator. Remove through bolts and withdraw slip ring end bracket and stator assembly. Carefully tap the mounting lugs with a mallet if necessary. 8. Remove nuts, washers and insulators from stud terminals noting their position for reassembly. Remove two screws and insulation cover and withdraw rectifier and stator from slip ring end bracket.

1.5W Max

13. Clean surfaces of slip rings using a solvent moistened cloth. 14. Inspect slip ring surfaces for signs of burning, remove burn marks using extra fine glasspaper. On no account should emery cloth or similar abrasives bc used, or any attcmpt made to machine the slip rings. 15. Check the insulation of the rotor field windings, using a suitablc 110 volt test lamp connccted betwccn one of the slip rings and onc of the rotor poles. If the test lamp lights, the rotor must bc rcncwed.

RR22 19M

9. Release the stator winding cable ends from the rectifier by applying a hot soldering iron to the terminal tags of the rectifier. Prise out the cable ends when t h e solder melts, and separate the rectifier and stator. Further dismantling of the rectifier is not required. 10. Check t h e diodes. Connect the test equipment as shown and test each diode in turn, note whether lamp lights, then reverse test lead connections. Thc lamp should light in one direction only. Rencw thc rectifier asscmbly if a faulty diode is diagnosed. 11. Visually inspect the stator windings for signs of damage or burning. Check the stator insulation using a suitable 110 volt test lamp. Connect the test leads to the laminated yoke and to each of thc three leads in turn. If test lamp lights, fit a ncw stator. i Z Kemove the fan and puiiey asscmbly. Piish oiit ihc rotor shaft from the bearing using a suitable prcss and remove t h e spacer from t h e shaft.

R R 2 2 2 1M

16. Check the resistance/continuity of the rotor field windings by connecting an ohmmeter to the slip rings as shown. A reading of 3.2 ohms should be obtained. 17. Check condition of bearings. If signs of rubbing between rotor Doles and stator is evident, both bearings are excessively worn, and must be renewed. 18. Use a suitable press, applying pressure from the rear of the slip ring end bracket, to withdraw or refit the bearing. Note that the drive end oracket and bearing are only supplied as a u n i t . gf---;

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26

ELECTRICAL EQUIPMENT- ALTERNATOR

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Assembling

19. Fit the spacer and press the rotor into the drive end bracket. Tnsert the through bolts. Fit the spacer, fan, pulley and spring washer to the shaft. Fit and tighten the pulley nut to the correct torque. 20. Fit the stator and rectifier assembly to the drive end bracket in the position previously marked. 21. Fit the slip ring end bracket in the position previously marked, locating the regulator lead through its aperture. Fit the insulation cover and tighten two rectifier securing screws. 22. Fit and tighten the through bolt nuts evenly and to the correct torque. 23. Connect the lead to the regulator, locate the brushes on the slip rings and secure t h e regulator/ brushbox assembly, taking care not to damage the brushes. 24. Fit both suppression capacitors. 25. Refit the alternator.

ALTERNATOR DATA

Manufacturer ............................................................ Type ................................... ............................ Polarity ................ ............................................ Maximum operating speed ....................... Maximum D C output at 6000 rev/min ............................. Stator windings .......................................................... Stator winding rcsistance .................. ....................... Regulator type .......................................................... Regulator controlled voltage ........................................ ......................... Field winding rotor poles .............. Rotor winding resistance ............................................. Brush length - new ........................ ....................... Renew regulator/brushbox assembly at ........................... Brush spring pressure - flush with brushbox moulding .........
TORQUE WRENCH SETTING

Lucas A 127/65 Negative earth 15000 rcv/min 65 amp 3 phase 0.15 ohm/phase 21TR 13.6-14.4V 12 3.2 ohms 17 mm (0.67 in) From 5 mm (0.20 in) moulding 1.3-2.7N (4.7-9.802)

Alternator shaft nut .................................................. Alternator through bolts ............................................ Alternator rectifier screws .......................................... Regulator/brushbox screws ........................................ Terminal nut - main output ......................................... Terminal nut - phase .................................................

Nm 50-70 5.5 3.5 2.5 4.0 4.0

Ibf ft 37-52 4.0 2.5 2.0 3.0 3.0

27

ELECTRICAL EQUIPMENT-ALTERNATOR
ALTERNATOR FUNCTIONAL CHECK

The alternator contains polarity sensitive components that could be permanently damaged if subjected to incorrect polarity. Do not connect or disconnect any part of the charging circuit - including t h e battery leads - while the engine is running. Run the alternator with all connections made or with the unit disconnected. This operation must be performed in two parts. Thc first to prove the alternator's capacity to produce current. The sccond to prove the performance of the integral regulator.
Check capacity to produce current NOTE: The stated output may be exceeded slightly when the alternator is cold. To avoid misleading results, the check should be performed with the unit as near to its normal operating temperature as possible.
1. Check drive belt adjustment. 2. Disconnect the multi-socket connector. 3. Remove the cover and provide a suitable probe and wire to enable the field winding earth brush to be earthed direct thus by-passing the regulator. 4. Provide a test circuit as shown below. A. Alternator B. Ammeter C. 12 volt battery D . Voltmeter E. Variable resistance

8. Hold the speed at approximately 6000 alternator rev/min (3000 engine rev/min). Adjust the variable resistor so that the voltmeter reads 14 volts. The
ammeter reading should now be approximately equal t o the nominal output given in data. 9. If the ammeter reading is not correct the indication is that the alternator requires overhaul or replacement.
Check control regulator NOTE: The stated output may be exceeded slightly when the alternator is cold. To avoid misleading results, the check should be performed with the unit as near to its normal operating temperature as possible.

10. Check drive belt adjustment. 11. Disconnect multi-socket connector. 12. Provide ;I test circuit as shown.

r"'
VOLTS

--a--!I

+I

5. Do not connect the variable resistor across the battery for longer than is necessary to perform the check. 6. Run the engine. 7. Gradually increase the speed. At 1550 alternator rev/min (775 engine rev/min) the light should be extinguished. 28

13. Start the engine and gradually increase t h e speed. At 1550 alternator rev/min (775 engine rev/min) the light should be extinguished. t h e speed at apprcjxima;c!j: 6ggg a!:ernato; 14. rev/min (3000 engine rev/min). The voltmeter reading should now be steady at 13.6 to 14.4 volts. 15. If the voltmeter reading is n o t steady at the above figure - and a satisfactory 'check capacity to produce current' has been performed - the indication is that the control regulator should be replaced.

g 2 .

y,

ELECTRICAL EQUIPMENT -ALTERNATOR

DIODE FAULT SYSTEM

186I

Failure of one or more of the diodes will be indicated by the output of the alternator and in some instances by an abnormally high temperature and noise level. The following fault symptom chart shows how diode failure will influence alternator test results.

Warning Light Illuminated at stand-still. extinguished at cut-in bpeed ( I ,5on revhnin) but at higher speeds becomes partially illuminated again and gets progressively brighter Not illuminated hetwceti zero at 1 ,500 rev/nun Illwninatcd at stand-still, dims appreciably at cut-in speed ( I ,500 rcv/min) and gets progrcssively dimmer o r may be extinguished at higher speeds Illuminated at stand-still. dims appreciably at cut-in speed ( I ,500 reviinin) and gets progi-essivcly dimmer or may be extinguished at higher speeds Illuminated at stand-still. dims iit Gut-in speed (1,500 rev/min) and remains dim, but may he zxtinguished ;it very high speeds Illuminated at stand-still, dims at :ut-in spectf ( I,500 rev/min) and remains dim. but may be

Teniperature High

Noise

output Higher than normal at 6,000 revimin. Approximately 40A

Probable Fault (Assnciated Damage)

Normal

Live-side main output diode open circuit. (May damage rotor field winding and regulator, overheat, brushboxes. and fuse warning light bulb) Live-side main output diode short circuit. (May darnage associated 'field' diode) Earth-side main output diode open circuit

High

Excessive

Very low at 6.000 rev/min Approximately IOA Poor at low speed Slightly below normal at 6,000 r e v h in. Approximately 32A Lower t h a n nornial a t 6,000 rev/ min. Approximately 29A

Nor ni a I

Excessive

Normal

Normil

'Field' diodc open-circuit

Normal

Excessive

Very low at all speeds above etiti n (1.500 r e v h i n ) .

Earth-side main output diode short-circuit, o r witor winding short-circuit t o earth 'Field' diode short-circuit

Normal

Vcry low ;it 6.000 revhnin Approximately 7A

ALTERNATOR FAULT AND DIAGNOSIS CHART

ALTERNATOR DOES N O T C H A R G E WORN O R SLACK BELT WORN O R DIRTY BRUSHES BROKEN O R FAULTY R O T O R WINDING BREAK IN C H A R G I N G CIRCUIT OPEN CIRCUIT OK FAULTY FIELD D I O D E FAULTY REGIJLATOR 2 OR 3 RECTIFIER D I O D E S O F S A M E POLARITY FAULTY WORN O R SLACK B E L T WORN O R DIRTY BRUSHES O N E O R M O R E DEFECTIVE RECTIFIER DIODES OPEN OR SHORT-CIRCUITED STATOR FAULTY R E G U L A T O R FAULTY CONNECTIONS FAULTY R E G U L A T O R FAULTY CONNECTIONS BETWEEN ALTERNATOR AND REGULATOR WORN BELT LOOSE PULLEY LOOSE ALTERNATOR MOUNTINGS MISALIGNMENT O F PULLEYS FAULTY BEAKING O N E OR S E V E R A L RECTIFIER DTODES OPEN O R SHORT-CIRC1IITEn SHORT-CIRCUITED STATOR
i

WEAK O R IRRF,GULAR C H A R G E

OVER CHARGE NOISY ALTERNATOR

CHECK EACH ITEM IN T U R N AND RECTIFY IF NECESSARY B E F O R E PROCEEDING TO N E X T ITEM.

29

86

ELECTRICAL EQ UIPMENT -DIESEL ENGINE STARTER MOTOR

Yoke assembly

DIESEL ENGINE STARTER MOTOR (2M113) DISMANTLE TEST AND OVERHAUL Solenoid Unit

8. Withdraw the yoke assembly complete with field

coils, brushes and seal (if fitted).
Drive end bracket
9. Remove the eccentric pivot pin. 10. Withdraw the drive-end bracket by releasing engagement lever from drive operating collar whilst the bracket is being removed.
continued

1. Disconnect link from starter terminal. 2. Unscrew and remove solenoid securing screws and withdraw the solenoid body. 3. Remove plunger complete with seal and nylon block (if fitted) by lifting front end of plunger to release it from the top of the engagement lever.
Commutator end bracket

4. Remove the two brush plate securing screws. 5 . Remove the two through bolts. 6. Withdraw the commutator end bracket and seal (if fitted). Note position of the dowel pegs in the end of commutator.
Brush plate assembly

7. Disengage the brushes and remove the brush plate assembly.

KEY TO STARTER MOTOR COMPONENTS 1. Solenoid 2. Solenoid - starterlink 3. Bracket assembly - commutator end 4. Brake assembly 5 . Brush box mounting plate assembly 6. Brush springs 7. Brush set 8. Field coil assembly 9. Engaging lever assembly 10. Bracket assembly drive-end 11. Retention assembly 12. Drive 13. Bracket assembly, intermediate 14. Armature 15. Bearing bush - set of three 16. Yoke

STl289M

30

ELECTRICAL EQUIPMENT -DIESEL ENGINE STARTER MOTOR

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Drive assembly and intermediate bracket

Armature

11. Drive the thrust collar back towards the drive pinion away from the jump ring. 12. Prise the jump ring from the groove in t h e drive shaft. 13. Remove the collar, drive pinion and intermediate bracket from the armature and note the position of the peg in the bracket.

26. Clean the armature with a petrol moistened cloth. 27. If growler equipment is available check for shortcircuited windi ngs. 28. Examine the commutator and if worn or damaged it can be skimmed provided that it is not machined below the minimum diameter of 38 mm (1.5 in). 29. Finally, finish the commutator with fine emery cloth. Do not undercut the commutator segments.
Insulation test

TEST AND OVERHAUL

Solenoid Windings 14. Check the continuity and resistance value of the winding, see technical data. If unsatisfactory renew the solenoid.
~

Check the insulation of the following components using a 110 V A.C. 15 watt test lamp: Field coils, armature commutator and windings, insulated brush boxes.
Field coil insulation

Solenoid Contacts

15. With the solenoid plunger removed, check, with an ohmmeter, the continuity across the main contacts. The reading should be infinity. 16. Fit the plunger and operate it, by hand, to close the contacts. If satisfactory the ohmmeter should register zero. 17. If one or both of the above tests prove unsatisfactory, renew or repair the solenoid. 18. Check the operation of all springs for freedom of movement.
Brush gear

30. Connect the test lamp between the yoke terminal and the yoke. Ensure that the brushes are not touching the yoke. The lamp should not light if the insulation is satisfactory. If the lamp does illuminate renew the field coil assembly.

19. Check the brushes for damage, wear and lcngth against the figures in the technical data. If necessary renew brushes, but see Field Coils first. 20. Before renewing brushes check the field coils and brush plate assembly. 21. If necessary, clean the brushes with a petrol moistened cloth. 22. Check the brush springs and ensure that the brushes move freely in their holders.
Drive pinion

STl290M

Armature insulation

31. Connect the test lamp between any one of the commutator segments and the armaturc shaft. The lamp should not light, if i t does replace the armature.

23. Examine the pinion for wear and damage. The pinion should rotate in one direction only, independent of the clutch body. Renew pinion if unsatisfactory.
Field coils 24. Inspect the coils for damage and ensure that the insulation tape is firm and not loose. Check all joints for continuity and evidence of burning which indicates an insulation fault. 25. If the brushes are being renewed cut the flexible leads leaving a sufficient length to enable the new brush leads to be joined with a soldered connection.

A3 ST 1 291M

31

86
i

ELECTRICAL EQUIPMENT- DIESEL ENGINE STARTER MOTOR

Solenoid

Brush box insulation

32. Connect the test lamp between a clean part of the bracket and each of the two insulated brush boxes in turn. If the test lamp lights renew the commutator end bracket assembly.
Bearing bushes

46. Ensure that the plunger locates properly with the operating lever.
Pinion setting

33. If the armature fouls the pole shoes or side play exists between the armature shaft and bush, renew the bearing bushes using a suitable hand press mandrel.

ASSEMBLE STARTER MOTOR

ReGassembly is mainly a reversal of the foregoing dismantling procedure. However, the following points should be observed.
Lubrication

34. Smear the drive shaft splines and the drive operating collar and bearing surface of the engagement fork with Shell Retinax A grease.
Armature

47. Screw the eccentric pivot pin fully into the casing and slacken one full turn and position as illustrated with arrow on the pin in line with the arrow on casing and tighten locknut. This provides an initial setting for final adjustment. 48. Connect up the starter, as illustrated, using a 6 volt supply and operate a starter control switch so that the pinion will move into the engaged position without rotating. 49. Whilst maintaining this position press back the pinion towards the yoke. Insert a feeler gauge between the pinion end face and jump ring collar. The correct clearance should be 0,13 to 0,38 mm (0.005 to 0.015 in). 50. If adjustment is required, release the locknut and turn the pivot pin as necessary to achieve the correct setting. Apply gold size to the threads of the pivot pin and locknut and tighten thc lattcr to the correct torque.

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/48

35. Ensure that the brake pin is tight and symmetrically positioned. 36. Check that t h e jump ring locates properly in the drive shaft groove and is covered by the thrust collar.
Drive-end and intermediate brackets

37. Ensure that the dowel peg in the drive-end bracket aligns with matching location in the intermediate bracket beforc offering the yoke into position.
Brush plate

38. Wedge the earth brushes in raised position with brush springs. 39. Offer thc brush plate into position and fit the field coil brushes in the boxes. 40. Release the earth brushes and position the springs. 41. Ensure that the brushes move freely in the holders.
Commutator end bracket

ST1292M

P 48

42. Check that the earth stud is fixed secureiy. 43. Ensure that the armature brake pin and slots in t h e brake shoes align with each other. 44. Make sure that the fixing holes in the brush plate line up with th holes in the commutator end bracket. 45. Check that the through bolts are aligned with the threaded holes in the drive-end bracket. 32

ELECTRICAL EQUIPMENT- DIESEL ENGINE STARTER MOTOR

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(86

TECHNICAL DATA Starter performance (2M113) Minimum battery requirement ................................

12 V 178 Ah (20 hr rate) battery at least 70% charged. 39.4 N m 4.0 Kg m 29.0 Ib ft 14.9 Nm 1.5 Kg m 11.0 Ib ft

Lock torque ........................................................

940 A max at 6.5 V min

Torque at 1000 rev/min .........................................

540 A max at 8.0 V min

Light running current ............................................

Solenoid Windings Resistance Operating winding resistance .................................. measured between small unmarked Lucar terminal and main terminal marked STA.

100 A max at 5,000 - 7,500 rev/min

0.145 - 0.165 ohms

Hold-on winding resistance .................................... measured between small unmarked Lucar terminal and earth point on solenoid body.
Brushgear New brush length ................................................. Renew brush at ................................................... Armature end-float Cast aluminium intermediate bracket ....................... Pressed steel intermediate bracket ........................... Commutator Commutator minimum diameter .............................

0.46 - 0.56 ohms

22.2 mm (Yx in) k 0.50 mm (0.020 in) 8 mm (Ain)

0.03 - 1.4 mm (0.001 -0.056 in) 0.03 - 1.55 mm (0.001 - 0.061 in)

38 mm (1.5 in)

...

TIGHTENING TORQUES

Solenoid main BAT terminal cablc fixing nut Solenoid/starter link terminal fixing nuts ................... Solenoid end cover fixing screws .............................. Solenoid unit fixing screws ........ Brush plate fixing screws ....................................... Starter earth stud, nuts ............... Pole shoe fixing screws .......................................... Through bolts ..................................................... Eccentric pivot pin locknut .....................................

3.9 Nm (2.9 Ib ft) 3.5 N m (2.6 Ib ft) 2.82 N m (2.1 Ib ft) 6 Nm (4.5 Ib ft) 7 Nm (5.0 Ib ft) 6 Nm (4.5 Ib ft) 40.68 Nm (30 Ib ft) 10.84 Nm (8 Ib ft) 20 N m (15.0 Ib ft)

33

I86 I

ELECTRICAL EQUIPMENT- V8 ENGINE STARTER MOTOR

TEST AND OVERHUAL Clutch

V8 ENGINE STARTER MOTOR (3MlOOPE) DISMANTLE TEST AND OVERHAUL DISMANTLE

1. Remove the starter motor. 2. Remove the connecting link between the starter and the solenoid terminal STA. 3. Remove the solenoid from the drive end bracket. 4. Grasp the solenoid plunger and lift the front end to release it from the top of the drive engagement lever. 5. Remove the end cap seal. 6. Using an engineers chisel, cut through a number of the retaining ring claws until the grip on the armature shaft is sufficiently relieved to allow t h e retaining ring to be removed.

16. Check that the clutch gives instantaneous take-up of the drive in one direction and rotates easily and smoothly in the other direction. 17. Ensure that the clutch is free to move round and along the shaft splines without any tendency to bind.
NOTE: The roller clutch drive is sealed in a rolled steel cover and cannot be dismantled.

18. Lubricate all clutch moving parts with Shell SB 2628 greasc for cold and temperate climates or Shell Retinax A for hot climates.
Brushes

19. Check that the brushes move freely in the brush 5 *q -: box moulding. Rectify sticking brushes by wiping %with a petrol-moistened cloth.

ST1293M

20. Fit new brushes if they are damaged or worn to approximately 9 3 mm (0.375 in). 21. Using a push-type spring gauge, check the brush spring pressure. With new brushes pushed in until the top of the brush protrudes about 1,5 mm (0.065 in) from the brush box moulding, dimension A, the spring pressure reading should bc 1,0 kgf (36 ozf).
continued

7. Remove the two through-bolts. 8. Partially withdraw the commutator end cover and disengage the two field coil brushes from the brush box. 9. Remove the commutator end cover. 10. Withdraw the yoke and field coil assembly. 11. Withdraw the pivot pin. 12. Withdraw the armature. 13. Using a suitable tube, remove the collar and jump ring from the armature shaft. 14. Slide the thrust collar and the roller clutch drive and lever assembly off the shaft.
34

21

ELECTRICAL EQUIPMENT -V8 ENGINE STARTER MOTOR

86

22. Check the insulation of the brush springs by connecting a 110 V A.C. 15W test lamp between a clean part of the commutator end cover and each of t h e springs in turn. The lamp should not light.

I.

Armature

1. 2. 3. 4. 5. 6. 7.

23. Check the commutator. If cleaning only is necessary, use a flat surface of very fine glass paper, and then wipe the commutator surface with a petrol-moistened cloth. 24. If necessary, the commutator may be machined providcd a finished surface can be obtained without reducing the thickness of the commutator copper below 3,5 mm (0.140 in), otherwise a new armature must be fitted. Do not undercut the insulation slots.

8.
9. 10. 11. 12. 13.

14. 15. 16. 17. 18.

KEY TO STAKTER MOTOR COMPONENTS Solenoid Solenoid plunger End cap seal Spire ring and bush Through bolts Brush plate brushes Commutator end cover Yoke and field coil assembly Retaining ring Pivotpin Armature Collar and jump ring Thrust collar and roller clutch drive and lever assembly Drive-end bracket and bush Rubber block Connecting link bctween starter and solenoid Intermediate bracket and seals Field coil brushes

ll0V

25. Check the armature insulation by connecting a 110 V A.C. 15 W test lamp between any one of the commutator segments and the shaft. The lamp should not light; if it does light, fit a new armature. 35

86

ELECTRICAL EQUIPMENT -V8 ENGINE STARTER MOTOR

SoIenoid
33. Disconnect all cables from the solenoid terminals and connectors. 34. Connect a 12 V battery and a 12 V 60 W test lamp between the solenoid main terminals. T h e lamp should not light; if it does light, fit new solenoid contacts or a new solenoid complete. 35. Leave the test lamp connected and, using the same 12 V battery supply, energizc the solenoid by connecting 12 V between the small solenoid operating Lucar terminal blade and a good earth point on the solenoid body. 36. The solenoid should be heard to operate and the test lamp should light with full brilliance, otherwise fit new solenoid contacts or a new solenoid complete.

Field coil insulation

26. Disconnect the end of the field winding where it is riveted to the yoke, by filing away the riveted over end of the connecting-eyelet securing rivet, sufficient to enable the rivet to be tapped out of the yoke. 27. Connect a 110 V A.C. 15 W test lamp between the disconnected end of the winding and a clean part of the yoke. 28. Ensure that the brushes or bare parts of thcir flexibles arc not touching the yoke during the test. 20. The lamp should not light; if it does light, fit a new field coil assembly. 30. Re-secure the end of the field winding to the yoke.

2' 7
STl297M

STl299M

ASSEMBLE
Field coil continuity

31. Connect a 12 V battery-operated test lamp between each of the brushes in turn and a clean part of thc yoke. 32. The lamp should not light; if it does light, fit a new field coil assembly.

/31

37. Fit thc intermediatc bracket and inner seal over the armature shaft. 38. Slide the thrust collar and the roller clutch drive and lever assembly onto the armature shaft. 39. Fit the jump ring and collar to the armature shaft. 40. Fit the armature. 41. Fit the pivot pin and splay the end. 42. Fit the yoke and field coil assembly and ensure that the dowel peg in the drive-end bracket aligns with matching location in the intermediate bracket before offering thc yoke into position. 43. Fit the internal thrust washer to the shaft. 44. Engage the two field coil brushes in the brush box and fit the commutator end cover. 45. Secure the assembly with the two through bolts and tighten to the correct torque. 46. Fit thc sintcrcd bearing bush.
continued

STI298M

36

ELECTRICAL EQUIPMENT- FOUR CYLINDER PETROL ENGINE STARTER

,
I,

1861

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47. Using a suitable tube, drive a new spire ring into position, as illustrated. The position of t h e spire ring on the armature shaft determines the armature end-float which should be 0,25 mm (0.010 in) maximum between the spire retaining ring and the sintered bearing bush shoulder. Care, therefore, must be used when fitting the spire ring.
Dimension A 25,4 mm (1.OO ins) Dimension B 19 mm (0.75 ins)

PETROL ENGINE 2.25 LITRE STARTER MOTOR (2M100) LUCAS. DISMANTLE TEST AND OVERHAUL DISMANTLE

1. Remove the nut securing the (solenoid-to-starter) connecting link to the solenoid STA terminal. 2. Pull back the connecting link from the solenoid terminal. 3 . Remove the nuts securing the solenoid to the drive-end bracket. 4. Remove the solenoid unit from the drive-end bracket. 5. Lift the solenoid plunger and return spring from the engagement lever. 6. Remove the block-shaped grommet.
NOTE: Before carrying out instructions 7 to 14 ensure that new retaining rings are available for the armature shaft and the engagement lever pivot pin are available for reassembly of the starter.

7. Remove the end cap seal. 8. Using an engineers chisel, cut through a number of the retaining ring claws until the grip on the armature shaft is sufficiently relieved t o allow the retaining ring to be removed.

48. Fit the end cap seal. 49. Fit the solenoid to the drive-end bracket whilst locating the drive engagement lever. 50. Fit the connecting link between the starter and solenoid terminal STA.

ST1301 M

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9. Remove thc through-bolts. 10. Detach the commutator end cover from the yoke, disengaging the field brushes from the brush box moulding, and remove the end-cover. 11. Remove the thrust washer from the armature shaft. 12. Withdraw the yoke from the armature and driveend assembly.
37

ELECTRICAL EQUIPMENT -FOUR CYLINDER PETROL ENGINE STARTER

13. Drive the pivot pin from the engagement lever and drive-end bracket. 14. Move the thrust collar clear of the jump ring, and remove the jump ring from the armature shaft. 15. Remove the thrust collar. 16. Remove the roller clutch drive and engagement lever assembly and intermediate bracket assembly from the armature shaft.
INSPECTION Brush gear

23. Polish the commutator with very fine sandpaper. 24. Using an air blast, clean any copper residue from the armature.
IMPORTANT: The commutator segment insulators must not be undercut. Armature

17. Check the brush spring tension using a spring balance; renew a spring if its tension is not within the limits given. 18. Check the brushes for wear; renew any brush worn to o r approaching the minimum length. 19. To renew a brush, unsolder the flexible connection, remove the brush and re-solder the flexible connection of the new brush in place. New brushes are pre-formed and do not require bedding to the commutator.
Commutator

25. Test the insulation of the armature windings with a 12-volt test lamp and battery connected between the armature shaft and the commutator; if the lamp lights the armature must be renewed. 26. Check the windings at their connections with the commutator riser for signs of melted solder or lifted conductors.
continued

20. Clean thc commutator with a cloth moistened with fuel and examine it for burns, pitting, and excessive wear. 21. Carry out instructions 22-24 to recondition t h e commutator. 22. Skim the commutator at high speed using a very sharp tool and removing the minimum amount of metal necessary to restore the surface.

KEY TO STARTER MOTOR 1. Nut securing connecting link to STA terminal 2. Drive-end bracket 3. Solenoid 4. Solenoid plunger and return spring 5 . Spirering 6. End cap seal 7. Throughbolts 8. Commutator end cover 9. Yoke 10. Field coil and brush plate brushes 11. Engagement lever 12. Pivotpin 13. Thrust collar and jump ring 14. Intermediate bracket 15. Roller clutch drive assembly 16. Bush

ST1305M

38

ELECTRICAL EQUIPMENT -FOUR CYLINDER PETROL ENGINE STARTER

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27. Check the shaft for distortion; if the shaft is bent or distorted the armature must be renewed. D o not attempt to straighten the shaft or machine the armature core laminations.

Roller clutch drive

43. Check the operation of the drive clutch, it should provide instantaneous take-up of the drive in one direction and rotate easily and smoothly in the other direction. 44. Check that the drive moves freely on the armature splines without binding or sticking.

Field windings

28. Connect a 12-volt battery-operated test lamp between each of the field brushes and a clean part of the yoke; the lamp will light if continuity is satisfactory between the brushes, windings, and yoke connection. 29. Disconnect the fieid windings from the riveted connection with the yoke. Using a 110-volt A.C., 15-watt test lamp connected between each of the brushes in turn and the yoke, check the insulation of the field windings, if the lamp lights the windings must be renewed. The field windings may be renewed as follows: 30. Disconnect the end of the field winding where it is riveted to t h e yoke. 31. Remove the four pole-shoe retaining screws using a wheel-operated screwdriver. 32. Withdraw the field coil assembly from the yoke. 33. Clean the inside of the yoke and insulating pieces which the through-bolts locate. 34. Loosely fit the new field coil assembly with the pole-shoes into the yoke. 35. Fit the pole-shoe retaining screws but do not tighten. 36. Slide the insulating pieces between the field coils and the yoke, positioned 90" each side of the field coil brush connection point. 37. Tighten the pole-shoe screws evenly using a wheeloperated screwdriver, to the correct torque. 38. Reconnect the end of the winding to the yoke.

ASSEMBLE
45. Reverse instructions 1 to 16 whilst observing the following instructions 46 to 48, also ensure that the dowel peg in the drive-end bracket aligns with matching location in the intermediate bracket before offering the yoke into position. 46. When assembling the drive-end bracket use a new engagement lever pivot pin, and splay the end. 47. Ensure that the internal thrust washer is fitted to the commutator end of the armature shaft before the armature end cover is fitted. 48. Using a suitable tube, drive a new spire ring into position, as illustrated. The position of the spire ring on the armature shaft determines the armature end-float which should be 0,25 mm (0.010 in) maximum between the spire retaining ring and the sintered bearing bush shoulder. Care, therefore, must be used when fitting the spire ring. Dimension A 25,4 mm (1.00 in) Dimension B (19 mm (0.75 in)

Commutator end bracket

39. Check the insulation of the brush springs by connecting a 110-volt A.C., 15-watt test lamp between a clean part of the commutator end cover and each of the springs in turn; the lamp will light if the insulation is not satisfactory.
STl302M

Bearings

..

40. If the bearings in the commutator end cover and the drive-end bracket are worn sufficiently to allow excessive side-play of the armature shaft. the bearing bush must be renewed as follows; instructions 41 and 42. 41. Support the bracket and drive out the bush using a suitable sized mandrel. 42. Using a polished, shouldered mandrel, the same diameter as the shaft bearing journal, press the new bushes into the brackets.

BENCH TEST
Lock torque and current

49. Clamp the starter firmly in a vice. Connect a starter switch, a 0-600 amp ammeter and a 12-volt battery in series to the starter. 50. Connect a voltmeter between the solenoid two main terminals. 51. Secure an arm to the driving pinion, and connect a spring balance to the free end o the arm. f 39

ELECTRICAL EQUIPMENT-FOUR CYLINDER PETROL ENGINE STARTER

52. Operate the switch and note the ammeter, voltmeter, and spring balance readings. Calculate the lock torque by multiplying the reading of the spring balance in pounds by the length of the arm in feet. 53. Check the readings obtained in instruction 52 against the figures given in DATA for lock torque current and voltage.
NOTE: If a constant-voltage supply is used for this test, a higher voltage may be registered on the voltmeter than the figure given. If this should occur a variable resistance must be added to the circuit and adjusted to give the required reading and the test repeated. Solenoid -Coil

56. Using an ohmmeter connected between the small unmarked Lucar terminal and a good earth on the solenoid body, check the resistance of the hold-on (shunt) winding; if the reading differs considerably from the limits given, the solenoid must be renewed.
Solenoid contacts

54. Check the continuity of the coil windings between the terminal STA and a good earth point on the solenoid body, using an ammeter (in series); a reading of 11.2 to 11.8 amps should be obtained. If no reading, rcnew the solenoid. 55. Using an ohmmeter connectcd between the small unmarked Lucar terminal and terminal STA check the resistance of the closing (series) winding; if thc rcading differs considerably from the limits given t h e solenoid must be rcnewed.

57. Check the contacts for correct opening and closing by carrying out the instructions 49 to 51 plus the following instruction 58. 58. Operate the switch and note the voltmeter rcading; it should register practically zero if the solenoid is satisfactory. Alternatively the solenoid should be checked by substitution. 59. The contacts must only be rcnewed as a set, e.g. moving and fixed contacts. The fixed contacts arc an integral part of the moulded cover. Renew a set of contacts by following instructions 60 to 66. 60. Remove the screws securing the terminal and base assembly to the solenoid. 61. Unsolder the coil connections from the cover terminals. 62. Clamp the solenoid in a vice. 63. Remove t h e tcrminal and base assembly. 64. Assemble the new terminal and basc asscmbly. 65. Rcsoldcr the connections to the terminal and basc assembly. 66. Refit the securing screws and tighten to corrcct torque.

. e\ g,;: 2

TECHNICAI, DATA

c
1,02 kg (36 oz) 9,5 mm (0.375 in) 3,5 mm (0.140 in) 2,02 kgm (14.4 Ib ft) with 463 amps 1,02 kgm (7.3 Ib ft) with 300 amps 40 amp at 6,000 r.p.m. (approx.) 0,25 mm (0.010 in)

Brush spring tension ............................................. ... Minimum brush length .................................. ..._. Minimum commutator thickness ............................. Lock torque ........................................................ Torque at 1,000 r.p.m. .......................................... Light runningcurrent ............................................ Maximum armature end-float .................................
Solenoid Closing (series) winding resistance ........................... Hold on (shunt) winding resistance ..........................

0.25 to 0.27 ohm 0.76 to 0.80 ohm

TIGHTENING TORQUES

Drive-end bracket nuts .......................................... Through bolts ..................................................... Pole-shoe screws .................................................. Solenoid base asse! . y screws ................................
40

6 Nm (4.5 Ib ft) 10 Nm (8 Ib ft) 40 Nm (30 Ib ft) 2 Nm (1.8 Ib ft)

ELECTRICAL E Q U I PM E N T
r

86

,. .*
I..

->

STARTER MOTOR Dismantle and Test

5.r

-Paris Rhone -4 cylinder Diesel

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.

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 t h e clutch drive and pinion assembly. 10. Withdraw the brushes from the holders.
Inspection and test

.
ST1847M

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

Field coil continuity

17. Connect a 12 V battery-opcrated test lamp between each brush in turn and a link lead. 18. The lamp should light; if i t does not light, fit a new field coil assembly.

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.

STl848M

ST1846M

,;:

. ... ..., . . . !. , .. . .

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

I86 I

ELECTRICAL EQUIPMENT
29. Fit the through-studs to the drive-end bracket. 30. Fit the brush plate cover and secure to the brush plate with the two nuts. 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.

i 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
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 , 4 N M 9,5 -C 1,5 NM 8,5 k 1,5 NM 4,2 _+ 0,6 NM 3,l -C 0,4NM

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 the :educ!ie:: gear heusing t G the d:ive=end bracket 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. 28, Insert the brushes into their holders and release the retaining springs. Ensure that the brushes rest correctly on t h e commutator.
42

ELECTRICAL EQUIPMENT

(861

.'

. .. ..,.

. . . . .

ST1833M

KEY TO STARTER MOTOR 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

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.

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.

ST1859M

/ /

4. Remove the bolt securing the front downpipe to the cylinder block.

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. Reposition 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 to the cylinder block with the single bolt.

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.

44

ELECTRICAL

86

45

I86 I
Solenoid

ELECTRICAL

Inspecting

23. Check the continuity and resistance value of windings by connccting an ohmmeter as shown.

RRl814E

RR1812E

(a) Resistance value should be: 1.074 k 0.035 ohms

Solenoid plunger operated by hand, ohmmeter should read zero. If test results are unsatisfactory, replace the solenoid. If results are correct proceed to 25. 25. Check operation of spring for freedom of movement.
Brush gear

g.2

g-x

(b)

26. Check brush springs and ensurc that the brushes move freely in their holders. Clean the brushcs with a petrol moistencd cloth, if requircd.

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.
RR1815E

24. Check the contacts by connecting an ohmmeter as shown. Solenoid plunger removed, ohmmeter should read infinity.

Brush length new, Dimension A is 9 mm (0.354 in). Minimum brush length, Dimension B is 3.5 m m (0.138 in).

46

ELECTRICAL
I *

186)

t! :;
,

Armature

.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.

33. Commutator end bracket; thread a &" Whitworth o r 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.
Reassembly

1w 5

11ov
RRl927E

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 Torque Wrench Settings.

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 o r 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 surrounding the head, side and flasher lamps. 3. Remove the three screws retaining the rim and light unit, and remove the rim. 4. Withdraw the light unit or reflector and pull-off the electrical connector. 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 reflector unit. 8. If required, fit a ncw bulb of the correct wattage and secure with the spring clip, as illustrated.

ST1839M

9. Remove the four screws and release thc headlamp shell from thc front wing. 10. Disconnect the electrical leads from the bullet connectors and remove t h e headlamp shell. 11. Remove the rubber seal. 12. Release the two trimmer screws and coil spring and detach the rim seating from the hcadlamp shell.

ST 1837M

48

ELECTRICAL EQUIPMENT- LAMPS

86

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 Aare measured horizontally on the vehicle and the dimension B vertically from the ground.

.
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 oclock position and the other 90 t o the Icft. 17. Secure the shell assembly to the wing with the four screws. 18. Offer-up the light o r reflcctor unit to the rim seating and connect the electrical plug.

_ . , _

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 REAR NUMBER PLATE LAMP Remove and renew bulbs

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.

1. Disconnect the battery and remove the single screw securing the lamp cover and lens. 2. A t 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 lamp to the vehicle body. 6. Remove the bulb holder complete with rubber seal 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 bottom. 8. Connect the electrical leads to the bullet connectors. 9. Fit the lamp to the vehicle, observing instruction 7, 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 mounting block, connect the leads and fit to vehicle body with the two screws and nuts. 8. Fit the bulbs. 9. Fit the lens and lamp cover and secure with single screw. Connect the battery and test lamp.

the the

the the

rf". *' -

50

ELECTRICAL EQUIPMENT -LAMPS

86

Renew the bulbs

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.

. . .
'. .

!k-k-i!
2
ST 1919M

INSTRUMENT ILLUMINATION
Renew bulbs

1. Disconnect the battery. 2. Remove the four screws rctaining the instrument panel. 3 . Ease forward the panel to gain access to the bulbs. 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

ELECTRICAL E Q U I P ME NT -WIPER MOTOR

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.

OVERHAUL WIPER MOTOR DISMANTLE

1. Removc :hc wiper motor and drive from the vehicle. 2. Remove t h e wiper motor gearbox cover. 3. Remove the circlip and plain washer securing the connecting rod. 4. Withdraw the connecting rod. 5 . Withdraw the flat washer. 6. Remove the circlip and washer securing the shaft and gear. 7. Clean any burrs from the gear shaft and withdraw the gear. 8. Withdraw the dished washer. 9. Add alignment marks to the yoke and gearbox for reassembly. 10. Remove the yoke securing bolts. 11. Withdraw thc yoke and armature. 12. Remove the brush gear assembly. 13. Remove the limit switch.
INSPECTION AND TEST

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.

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.

MOTOR COMPONEN1S KEY TO 1. Flexible drive 2. Gearboxcover retaining washer and circlip 3, 4. Connecting-rod 5 . Flat washer 6. Gear shaft retaining washer and circlip 7. Drivegcar 8. Dished washer 9. Alignment marks - yoketo body 10. Yoke securing bolts 11. Armature and yoke 12. Brush gear assembly 13. Limit switch

ST1303M

52

ELECTRICAL EQUIPMENT-WTPER MOTOR

20. Fit the armature and yoke to gearbox using 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 t h e gear wheel. 22. Fit the gear wheel to the gearbox. 23. Secure the gear wheel shaft with the plain washer and circlip. 24. Fit the larger flat washer over the crankpin. 25. Fit the connecting rod and secure with the smaller plain washer and circlip. 26. Fit the gearbox cover and secure with the rctaining screws. 27. Connect the electrical leads between the wiper motor and limit switch.

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.

DATA
Windscreen wiper motor Armature end-float ........................................... Brush length, minimum ......................................... Brush spring tension. ............................................ Resistance of armature winding at 16C (69F) measured between adjacent commutator segments.. .... Light running, rack disconnected: Current at 13.5 V .... Speed, 60 seconds from cold -Low speed.. ............... - High speed. ...............

0 , l to 0,2 mm (0.004 to 0.008 in) 4,8 mm (0.190 in) 740 to 200 g (5 to 7 0 2 ) 0.23 to 0.35 ohms 2.0 amps 45+ 3 rev/min 65.+ 5 rev/min

53

ELECTRICAL EQUIPMENT- FAULT TRACING

ELECTRICAL EQUIPMENT FAULT TRACING INTRODUCTION Fuses

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 manufacturer's operating instructions must be followed.
SYSTEMATIC DIAGNOSIS

Check for obvious signs of overload or short circuit before renewing a blown fuse or resetting an overload cut-out. Under n o 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

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, d o 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 o r 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

ABBREVIATIONS A. Amperes Ah Ampere-hour Centigrade (Celsius) C d.c. Direct current F Fahrenheit H.T. High tension in Inch

L.T. Low tension mm Millimetre rev/min revolutions per minute v . Volts temperature Degree
0

Percentage

panu!wos
isai-ai pue diaiieq aSieq3

OLO' I - OSO' I

OEI'I -011.1
OSZ' I OEZ' I

061'1 - 0 L I ' I

OEZ'I -012.1

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ISJ.1

ault attery not being charged AUTION: The vehicle attery must never be isconnected while the mgine is running i'arning light stays on Varning light does not function then ignition switched on

Check
1,293949 5

Test

Rectification

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
(ii) Ammeter reading below 10A, voltmeter reading between 13.6 and 14.6 V and battery in low state of charge (iii) Ammeter reading below IOA, voltmeter reading below 13.6V

Overhaul alternator Bench test and overhaul Renew voltage regulator Renew voltage regulator Adjust or renew

(iv) Ammeter reading above 10A, voltmeter reading above 14.6V

6. Drive belt: Check the drive belt is not broken or slipping
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

Repair or renew Carry out Test 5

Renew Carry out Test 9

(ii) E3ulb not faulty rEST EQUIPMENT r'oltmeter 0 20 V moving coil immeter 5-0-60A moving coil fydrometer

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

Carry out Test 5 Check cable continuity; repair or renew

(ii) Voltmeter does not read 12V- cable circuits faulty

IGNITION SYSTEM Engine will not tire
10,11,12,13, 1 4 , l 10. Engine cranking speed: Too low

See STARTING SYSTEM Clean. set gaps or renew contact breaker distributors carry out Test 12 Clean, adjust or renew Rectify or replace. Carry out Test 14. Rectify o r replace. Carry out Test 14.

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
~

13. Distributor cap: Check for 'tracking' (thin lines of burned bakelite), ensure cap i s clean and dry and that the centre brush moves freely with no excessive side movement and contacts the rotor arm.

continued

,. .,, . : ..... .., . .-. .. .

. . I

.. .. . ., .. . ..

.. :. . . .. . ..... . ... .

ault

Check lest 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 (ii) Above 0.2VHigh resistance or open circuit in distributor

Rectification

;NITION SYSTEM

Remake earth connections between distributor body and earth 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 i n 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- Shortcircuit 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 1 5 ~

(ii) Zero - reconnectcoil 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 5V - 7V with ballast resistor

Renew coil Fault elsewhere

If result of Test 15f was above 12V L.T. circuit is satisfactory

(iii) Below 1 l . W or zero without ballast resistor -Excessive resistance or open circuit supply to coil. Leaving the voltmeter connected t o 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 o r open circuit in supply to coil Connect 0 - 20 V voltmeter between earth and the lead from the ballast resistor to the coil positive terminal, with the ignition o n and contact breaker points closed: (i) 5V - 7V or above 12V - Fault in the ballast resistor to coil lead (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 - Faultin ballast resistor (ii) Zero or below I 1 . 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. continued

Rectifv 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 Rectify and re-test. I f satisfactory fault elsewhcrc

'ault
GNITION SYSTEM

Check

Test
14. H.T. Circuit

Rectification

Disconnect main H.T. lead from distributor cap, hold approximately 6 m m (V4 in) from a good earth, ensure contact breaker points are closed, switch on ignition and flick contact breaker points open.

k l
ST1307M

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

Carry out Test 14e Carry out Test 14b

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

Renew main H.T. lead. Carry out Test 14e Carry out Test 14c

Renew condenser. Carry out Test 14e Carry out Test 14d

ST1308M

Renew coil, refit original H.T. lead and condenser and repeat Tests 14a and b, or carry out Test 14e

rEST EQUIPMENT :A) Voltmeter 0 20V moviing coil :B) Voltmeter 0 1V movin;gcoil

e.

Dhmmeter
15. a.

b.

c.

Hold loose end of main H.T. lead approximately 3 mm ('/I from the rotor arm in) 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 L,.T. circuit continuity check: 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) Below 0.2V - Resistanceor 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 continued

Renew rotor arm Carry out Test 15 See STARTING SYSTEM

Carry out Test 15e Carrv out Test I5c

Renew lead Carry out Test 15d

auk

Checl

'est 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 0.2VHigh resistance or open circuit in distributor

Rectification

;NITION SYSTEM ,ontinued)

Remake earth connections between distributor body and earth Checkhepair or renew contact breaker points, base plate screws earth lead or supply lead as necessary

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

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

(ii) Zero - reconnectcoil -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 (ii) 1 1 S V - 12V without ballast resistor 5V - 7V with ballast resistor

Renew coil Fault elsewhere Rectify and recheck

If result of Test 15f was above 12V L.T. circuit is satisfactory

(iii) Below 1 1 . 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 o r open circuit in supply t o 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

Carry out Test 15h

Repair or renew lead then re-test Carry out Test 15j

(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 (ii) Zero or below 1 1 . 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. continued

Renew and re-test. If satisfactory fault elsewhere Rectify and re-test. If satisfactory fault elsewhere

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86 I

ELECTRICAL EQUIPMENT -FAULT TRACING

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Fault STARTER SYSTEM

Check
25. Drive faulty

Rectification

a.

Remove starter: check condition of pinion and starter ring gear Inertia drive, check that pinion rotates freely Check that crankshaft rotates freely Lock torque, free running speed and current

a. Renew pinion or ring gear

b.
c. d.

b , Renew inertia drive

c. Check for engine fault, tight or siezed

d. Check brushes - overhaul starter

See IGNITION SYSTEM

26. Ignition circuit fault

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FOUR CYLINDER PETROL

JB

1
77

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KEY TO FOUR CYLINDER PETROL DIAGRAM

2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

I . Speedlometer illumination Fuel indicator illumination

Water temperature illumination Rear log lamps Number plate lamp LH tail lamp LH side lamp RH tail lamp RH side lamp LH headlamp dip beam RH headlamp dip beam LH headlamp main beam R H headlamp main beam Interior lamp Stop lamp Horn LH side repeater LH front indicator LH rear indicator R H front indicator R H rear indicator RH side repeater Auxiliary instrument illumination Panel illumination switch Rear fog switch Interior lighting switch Washer pump Steering column switches Grouped warning lights (comprising items 3,0 to 43)

30. 31. 32. 33. 34. 35. 36.

Trailer warning light Side light warning light Rear fog warning light Main beam warning light Spare position Low fuel warning light Locked four-wheel drive warning light 37. Cold start warning light 38. Oil warning light 39. Charge warning light 40. Brake warning light 41. Park brake warning light 42. Direction indicator warning light 43. Seat belt warning light 44. Locked four-wheel drive switch 45. Clock 46. Reversing lamps 47. Wiper motor 48. Reversing lamp switch 49a Brake fluid loss switch (Ninety models only 49b Pressure differential warning actuator switch (One Ten models only) 50. Heater switch 51. Stop lamp switch 52. Flasher unit 53. Oil pressure switch
Key to cable colours

54. 55. 56. 57. 58. 59.

60. 61. 62. 63.

64. 65. 66. 67.

68.
69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81.

Brake check relay Park brake switch Light switch Pick-up point for front fog lamps Fuses Heater motor Hazard switch Hazard switch illumination Ignition light resistor Starter solenoid Spare pick-up point Start relay Distributor Pick-up point for auxiliary trailer Fuel indicator Water temperature indicator Oil pressure indicator Oil temperature indicator Battery Alternator Start switch Coil Battery condition indicator Pick-up point for auxiliary instrument illumination Fuel tank unit Water temperature transmitter Oil pressure transmitter Oil temperature transmitter

R Black G Green K Pink

L Light N Brown 0 Orange P Purple R Red S Slate

The last letter of a colour code denotes the tracer colour

U Blue W White Y Yellow

Connectors via plug and socket

Snap connectors

Permanent in-line connections

Earth connections via cables

Earth connections via fixing t~olts

FOUR CYLINDER 2.25 DIESEL,

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KEY TO FOUR CYLINDER 2.25 LITRE DIESEL DIAGRAM

1. Speedometer illumination

Fuel indicator illumination Water temperature indicator illumination Rear fog lamps (when fitted) Number plate lamp LH tail lamp LH side lamp R H tail lamp 9. RH side lamp 10. LH headlamp dip beam 11. R H headlamp dip beam 12. LH headlamp main beam 13. R H headlamp main beam 14. Interior lamp 15. Stop lamp 16. Horn 17. LH side repeater (when fitted) 18. LH front indicator 19. LM rear indicator 20. R H front indicator 21. R H rear indicator 22. R H side repeater (when fitted) 23. Pick-off point for auxiliary instrument illumination (when fitted) 24. Rear fog switch (when fitted) 25. Washer pump 26. Panel illumination switch 27. Interior light switch 28. Steering column switches 29. Grouped warning lights (comprising items 30 to 43)
2. 3. 4. 5. 6. 7. 8.

30. Trailer warning light 31. Side light warning light 32. Rear fog warning light 33. Main beam warning light 34. Spare 35. Low fuel warning light 36. Locked four-wheel drive warning light 37. Cold start warning light 38. Oil warning light 39. Charge warning light 40. Brake warning light 41. Park brake warning light 42. Direction indicator warning light 43. Seat belt warning light 44. Locked four-wheel drive switch 45. Clock (when fitted) 46. Reversing lamps (when fitted) 37. Wiper motor 48. Reversing lamp switch (when fitted) 49. Pressure differential warning actuator switch 50. Heater switch (when fitted) 51. Stop lamp switch 52. Flasher unit 53. Oil pressure switch 54. Brake check relay 55. Park brake switch (when fitted) 56. Pick-off point for front fog lamps (when fitted)
Key to cable colours

57. 58. 59. 60. 61. 62.

63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 75. 79. 80. 81. 82. 53.

Light switch Heater plugs Fuses Heater motor (when fitted) Hazard switch (when fitted) Hazard switch illumination (when fitted) Starter solenoid Spare pick-up point Pick-off point for auxiliary trailer Fuel indicator Watei temperature indicator Oil pressure indicator (when fitted) Oil temperature indicator (when fitted) Battery Alternator Fuel shut off valve Heat/Start switch Ballast resistor Battery condition indicator Fuel changeover relays (when fitted) Pick-up point for auxiliary instrument i 11u ni i n a t ion (when fitted) Rear tank unit Fuel cock switch (when fitted) Side tank unit Water temperature transmitter Oil pressure transmitter (when fitted) Oil temperature transmitter (when fitted)

B Black G Green K Pink

L Light N Brown 0 Orange P Purple R Red S Slate

The last letter of the colour code denotes the tracer colour

U Blue \V White Y Yellow

Connectors via plug and socket

Snap connectors

Permanent in-line connections

Earth connections bia cahles

Earth connections via fixing bolts

FOUR CYLINDER 2.5 LITRE DIESEL

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KEY TO FOUR CYLINDER 2.5 LITRE DIESEL DIAGRAM

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21, 22. 23.

24. 25. 26. 27.

28.
29.

Speedometer illumination Fuel indicator illumination Water temperature indicator illumination Rear fog lamps Number plate lamp LH tail lamp LH side lamp R H tail lamp R H side lamp LH headlamp dip beam R H hicadlamp dip beam LH headlamp main beam R H headlamp main beam Interior lamp Stoplamp Horn LH side repeater LH front indicator LH rear indicator R H front indicator R H rear indicator R H side repeater Pick-off point for auxiliary instrument illumination Rear fog switch Washer pump Panel illumination switch Interior lighting switch Steering column switches Grouped warning lights (comprising items 30 to 43)

30. 31. 32. 33. 34. 35. 36.

Trailer warning light Side light warning light Rear fog warning light Main beam warning light Spare Low fuel warning light Locked four-wheel drive warning light 37. Cold start warning light 38. Oil warning light 39. Charge warning light 40. Brake warning light 41. Park brake warning light 42. Direction indicator warning light 43. Seat belt warning light 44. Locked four-wheel drive switch 45. Clock 46. Reversing lamps 47. Wiper motor 48. Reversing lamp switch 49a Brake fluid loss switch (Ninety models only) 49b Pressure differential warning actuator switch (One Ten models only) 50. Heater switch 51. Stop lamp switch 52. Flasher unit 53. Oil pressure switch

54. Brake check relay 55. Park brake switch 56. Pick-off point for front fog lamps (when fitted) 57. Light switch 58. Heater plugs 59. Fuses 60. Heater motor 61. Hazard switch 62. Hazard switch illumination 63. Ignition light resistor 64. Starter solenoid 65. Spare pick-up point 66. Pick-off point of auxiliary trailer 67. Fuel indicator 68. Water temperature indicator 69. Oil pressure indicator 70. Oil temperature indicator 71. Battery 72. Alternator 73. Fuel shut off valve 74. Heat/Start switch 75. Battery condition indicator 76. Pick-up point for auxiliary instrument illumination 77. Fuel tank unit 78. Water temperature transmitter 79. Oil pressure transmitter 80. Oil temperature transmitter

Key to cable colours

R Black G Green K Pink

L Light N Brown

0 Orange P Purple R Red S Slate

U Blue W White Y Yellow

The last letter of a colour code denotes the tracer colour

Connectors via plug and socket

Snap connectors

Permanent in-line connections

Earth conneciions via caliles

Earth connections via fixing holts

V8 CYLINDER PETROL

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KEY TO V8 CYLINDER PETROL DIAGRAM

1. Speedometer illumination 2. Fuel indicator illumination 3. Waier temperature illumination 4. Rear fog lamps 5. Nurnber plate lamp 6. L H tail lamp 7. L H side lamp 8. R H tail lamp 9. R H side lamp 10. LH headlamp dip beam 11. R H headlamp dip beam 12. LH headlamp main beam 13. R H headlamp main beam 14. Interior lamp 15. Stop lamp 16. Horn 17. L H side repeater 18. LH front indicator 19. LH rear indicator 20. R H front indicator 21. R H rear indicator 22. R H side repeater 23. Pick-off point for auxiliary instrument illumination 24. Panel illumination switch 25. Rear fog switch (when fitted) 26. Interior light switch 27. Washer pump 28. Grouped warning lights (comprising items 29 to 42) 29. Trailer warning light

30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50.

51.
52. 53. 54. 55. 56. 57.

Side light warning light Rear fog warning light Main beam warning light Spare position Low fuel warning light Locked four-wheel drive warning light Cold start warning light Oil warning light Charge warning light Brake warning light Park brake warning light Direction indicator warning light Seat belt warning light Locked four-wheel drive switch Clock (when fitted) L H Reversing lamp R H Reversing lamp Steering column switches Wiper motor Reversing lamp switch Pressure differential warning actuator switch Heater switch Stop lamp switch Flasher unit Oil pressure switch Brake check relay Park brake switch Pick-off point for front fog lamps (when fitted)
Key to cable colours

58. Light switch

59. Fuses 60. Heater motor 61. Hazard switch 62. Hazard switch illumination 63. Ignition light resistor 64. Starter solenoid 65. Spare pick-off point 66. Start relay 67. Coil 68. Distributor 69. Pick-off point for auxiliary trailer 70. Fuel indicator 71. Water temperature indicator 72. Oil pressure indicator 73. Oil temperature indicator (when fitted) 74. Battery 75. Alternator 76. Start switch 77. Fuel pump 78. Ballast resistor 79. Battery condition indicator 80. Pick-off piont for auxiliary instrument illumination 81. Tank unit transmitter 82. Water temperature transmitter 83. Oil pressure transmitter 84. Oil temperature transmitter 85. Ignition module (when fitted)

BBlack GGreen KPink

LLight N Brown OOrange

PPurple RRed SSIate

UBlue W White Y Yellow

The last letter of a colour code denotes the tracer colour

B
Connectors via plug and socket Snap connectors Permanent in-line connections Earth connections via cables Earth connections via fixing bolts

186I

ELECTRICAL EQUIPMENT- CIRCUIT DIAGRAM

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72

KEY TO COMPOSITE CIRCUIT DIAGRAM

I . Battery condition indicator illumination 2. Cigar lighter illumination 3. Oil temperature indicator illumination 4. Water temperature indicator illumination 5. Fuel indicator illumination 6. Speedometer illumination 7. Door switches (when fitted) 8. Rear fog lamp 9. Reverse lamp IO. Number plate lamp 1 1 . L H tail lamp 12. LH side lamp 13. R H tail lamp 14. R H side lamp 15. L H headlamp main beam 16. R H headlamp main beam 17. LH headlamp dip beam 18. R H headlamp dip beam 19. Interior lamp (when fitted) 20. Interior lamp switch 21. Horn 22. Stoplamp 23. LH side repeater 24. L H front indicator 25. LH rear indicator 26. R H side repeater 27. R H front indicator 28. R H rear indicator 29. Front fog feed 30. Rear fog switch 31. Reverse lamp switch 32. Washer pump 33. R H washer pump connection 34. L H washer pump connection 35. Steering column switches 36. 'Trailer warning light 37. Side light warning light

38. Rear fog warning light

39. 40. 41. 42. 43. 44.

45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56.
57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73.

Main beam warning light Spare Low fuel warning light Locked 4WD warning light Spare Cold start warning light Locked 4WD switch Spare Oil warning light Ignition warning light Brakes warning light Park brake warning light Spare Direction indicator warning light Spare Seat belt warning light Wiper motor Norwegian daytime running lights connection German fuel shut off and Norway connections Oil pressure switch Pressure differential warning actuator switch Park brake switch (when fitted) Seat belt switch (when fitted) Fuses Clock (when fitted) Stop lamp switch Brake check relay Heater connections Flasher unit Ignition light resistor Light switch Auxiliary Hazard unit Starter solenoid Cigar lighter (when fitted) a) Australia b) Rest of World Key to cable colours

74. 75. 76. 77. 78. 79. 80. 81. 82. 83. 84. 85. 86. 87. 88. 89. 90. 91. 92. 93. 94. 95. 96. 97. 98. 99. 100. 101. 102. 103. 104. 105. 106. 107. 108. 109. 110.

Start relay Spares Auxiliary instrument illumination Spare auxiliary instrument Spare Starter inhibitor switch (auto only) Fuel pump (petrol only) Connector - Diesel Connector - common Connector- petrol Fuel indicator Water temperature indicator Oil temperature indicator Alternator Petrol ignition switch Diesel ignition switch Feed snap connector Feed snap connector Ignition snap connector Starter snap connector Auxiliary snap connector Heater snap connector Fuel shut-off snap connector Battery Battery condition indicator (when fitted) Radio (when fitted) Tank unit - fortwin tanks system Water temp transmitter Oil temperature transmitter (when fitted) Glow plugs (Diesel only) Fuel shut off solenoid (4 cylinder petrol only) coil Distributor (4 cylinder petrol only) 2 CE unit -V8 only Distributor- V8only Choke switch (petrol only) Air conditioning feed (when fitted)

BBlack GGreen K R n k

LLight N Brown OOrange PPurple R Red SSlate The last letter of a colour code denotes the tracer colour

UBlue W White Y Yellow

B
Connectors via plug and socket Snap connectors Permanent in-line connections Earth connections via cables Earth connections via fixing bolts

I86

ELECTRICAL EQUIPMENT- CIRCUIT DIAGRAMS

DIM-DIP CIRCUIT -UNITED KINGDOM ONLY

30
15

BATTERY

IGNITION

r-iJ 1

I
R E A R FOQ
INHIBIT RELAY

HEAD SWITCH

.-.

Thc in-line connections lettered A , B, C, D, E and F connect into the corresponding ILttered connections in thc main composite circuit diagram.

74

ELECTRICAL EQUIPMENT- CIRCUIT DIAGRAMS

CIRCUIT DIAGRAM - TWIN TANK - TWIN PUMPS

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1. Low fuel warning light 2. Fuelgauge 3. Relay 28RA low level warning 4 Relay 28RA Fuel gauge 5 . Relay 28RA Fuel pumps 6. Rear tank unit 7. Side t a n k unit

75

86

ELECTRICAL E Q UIPMENT- CIRCUIT DIAGRAMS

23

7
ST1827M

, 7
Y
POWER WASH SYSTEM
1. 2. 3. 4. 5. 6.

A8
Power wash timer Ignition feed Screen wash pump Screen wash switch Dipswitch Power wash pump
continucd

KEY TO TERMINATIONS

1. 28 RA Rclay (normally closed position) 2. 4 way moulded connecting tube 3. 6 way moulded connecting tube 4. Pin and socket connector 5. Clinch connections 6. Earth connections via cables 7. Fuse conneclions 8. Bulb connections

2
t

ST1824M

CIGAR LIGHTER
1. 2. 3. 4. 5. 6.

Ignition feed Side light circuit Baiiery pusiiive Cigar lighter Australia Only (dotted line) Standard Circuit (solid line)

76

ELECTRICAL EQUIPMENT- CIRCUIT DIAGRAMS

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I

1861

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ST1823M

REAR WASH-WIPE SYSTEM

I . Washer pump

2. Ignition feed

3. Sampfuse 4. Wiper switch

5. Wipcr motor

4
1 1

WG

WG

BK

NW

WE

p
b

ST1825M

53 6 32

10

11

HEATED REAK WINDOW

1. Voltage sensitive switch

2. 3. 4. 5. 6.

Starter solenoid Battery Heated rear window warning light Ignition feed Battery positive

7. 8. 9. 10. 11.

Heated rear window switch Heated rear window relay Diode 10 amp fuse Heated rear window

77

PRINTED IN ENGIAND BY COVENTRY PRINTERS 15187 37210)