1993 90 TDI 200 -. Getting to the starter...

Nickds · Mar 17, 2021

Hi,
My 90 is not turning over at all... I hear the relay and possibly the solenoid, but not a hint from the starter...

I need to get to the starter which is not that easy... It could be the solenoid, the earth strap, the positive feed or the actual starter... It might even be the relay clicking but the contacts failing, or the cable from there to the solenoid...

I need to get to the starter to check these things and that means removing the downpipe. I've taken the heat shield off, loosened the clamp to the manifold, undone the exhaust mounts (two M6 bolts to the block) and the joint to the silencer (two nuts), but can I shift it? No.

What am I missing here (apart from a normal life)? Is there a trick to this? Why did I buy this car?

Thanks

Pikey · Mar 17, 2021

lie underneath & belt the fecker its only got 2 bolts on it ya know

Knappster · Mar 17, 2021

Is it a disco 200Tdi? If so, the starter is hidden behind the Dow pipe and is a bit harder to get out if you need to remove it.

Cavey_P38 · Mar 17, 2021

i can get at mine with it all in situ< 200tdi disco engine in a 90 certainly enough to remove all the cables and clean contacts, had to do mine today during the FIp reinstall as the begger wouldn't turn over spade end off on the starter.

removal of starter it may or may not depends on how much wiggling and effort you put in i seem to remember, certainly you can get at all the bolts.

Unclip the bonnet catch and lay it back against the windscreen ( carefully gives you more access) use a bungay cord to the door to keep it there.

miktdish · Mar 18, 2021

Here's a picture of mine (a 300tdi) with the manifold removed. There are 9 studs and two bolts ... I think this is the same as the 200tdi ?

miktdish · Mar 18, 2021

Scooby22 · Mar 18, 2021

My first obvious thought is are you sure your battery is not flat or knackered, clicking solenoid is a classic sign of that.

Nickds · Mar 18, 2021

Scooby22 said:
My first obvious thought is are you sure your battery is not flat or knackered, clicking solenoid is a classic sign of that.

First thing I checked - battery is fine - 100% charged (12 hours on a charger) and not shagged (only a couple of years old). I also had it checked by a battery shop who said it was fine, plus I also used a known good big volvo battery with same result.

Europa486 · Mar 18, 2021

Earth point from chassis to engine always very suspect, I had a sticking solinoid on one of mine
And short sharp thump with a bar and Land Rover tool no 1 ( hammer) sorted it out,

lynall · Mar 18, 2021

Genuine 200tdi defender, starter can be changed in situ with down pipe still fitted, BUT and there is always a BUT you have to fit the low tension wire to the solenoid connector before you bolt the motor up as you cannot get at in once fitted.
I had the starter solenoid low tension wire come loose a couple of times, also went through a couple of starter motors.

The low tension wire (fat white thing) runs on top of solenoid to the back of the engine, have a look/test wiggle you never know?

As said standard earths are utter crap, needs two, both from bat neg, one to chassis and other to flywheel housing bolt, I also have one at front of engine to chassis.

Ps I dont think 200 has a starter relay? the fat white wire comes direct from the ign switch itself

Nickds · Mar 18, 2021

Hmmm. The bolts at the rear end of the downpipe are welded to the downpipe and thus can't be completely removed, so even with the two nuts undone, the downpipe won't come off as it won't go far enough forward to allow the studs to clear (it jams on an engine mount)...
Why is there no such thing as a simple job?

I have massive lumpy hands so can't get in without removing the downpipe, but it's looking as I've now got to take the exhaust middle section off too.

It's started to rain. I'm going to have a pint of tea and and listen to something calming on the hifi....

Cavey_P38 · Mar 18, 2021

I would check and recheck earths first maybe get a jump lead and create a temp one

if you have to dismantle then other option is manifolds off and split it there as you will have loads of room then, just be careful with oil feed pipe to the turbo

If you have not done the manifolds before then, you need to do inlet first. 4 bolts

then exhaust, you have to remove turbo oil pipe to get access to the last bolt in the middle.

then ease the exhaust manifold and turbo back towards inner wing, you can then access the big nut on the block which is for oil supply to Turbo 30mm i think

frog hopper · Mar 19, 2021

I can't remember how on my factory 200Tdi, but I took my starter off to clean/lube without taking off the manifolds, I don't think I took the downpipe off either. Of course a year later it all had to come off again as it had totally failed this time. ARSE. I do remember it was a hell of a faff getting the thing out.

Nickds · Mar 19, 2021

Done! What a palava....

Managed eventually to get old one out and took it to Curd Bros. in Tunbridge Wells... Fantastic place full of ancient equipment and old men in brown overalls hunched over wooden benches rebuilding vintage starters and alternators (they do a lot of vintage tractors apparently).

They tested my starter on a bit of kit that looked like a prop from the Munsters or a Hammer horror film...

...it was dead...

So they sold me a rebuilt one at a decent price. Installed it and car now starts instantly...

Happy. And yes, I had to use a lump hammer on a couple of stubborn items...

1993 90 TDI 200 -. Getting to the starter...

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