Starter motor change

toms3 · Jan 26, 2015

Hi guys iv got a bit of a problem with my starter motor, it just clicks once when I turn the key. Sometimes it takes 20 - 30 attempts before it will turn over! It's had a new battery and the alternator is fully working so it must be the starter at fault.

It's a 1987 90 with a discovery 200 tdi engine fitted. The starter motor is behind some exhaust pipes and looks like I'll need to remove them to get to it. My only worry is that it looks very close to the bulkhead to slide backwards (hope this makes sense). Has anyone changed one on a 200 tdi disco transplant into a 90 and did it have enough room behind to be removed without taking the engine out?

Cheers! Tom.

the_wolf · Jan 26, 2015

It is ####ing awkward. Really really awkward. You'll need to remove the intercooler and whatever else you can to get it out. Prepare for much anger, throwing of tools and swearing

toms3 · Jan 26, 2015

Yes I thaught that may be the case! Have I got this right? - remove inter cooler pipe, exhaust manifold and down pipe and it slides off in the direction of away from the bulkhead?.

Iv had a good search and a good nosey under the Bonet and that's what it looks like I need to do.

Is there 2 bolts - one either side to undo?

the_wolf · Jan 26, 2015

3 bolts total, one underneath too. Remove the exhaust downpipe and the intercooler/manifold. That should give you enough access

IamRobbie · Jan 26, 2015

worst job ever!! i wish u all the luck, next time my starter packs in I'm burning the truck rather than changing that thing again!!

i didnt bother with intercooler pipes i think it just took a lot of fiddling and all the skin off my knuckles and it came out, same ball ache going back in!

Good luck

Marmaduke · Jan 26, 2015

Reading this I'm glad I chose a 300tdi.

Soz:high5:

toms3 · Jan 26, 2015

Cheers guys! I thaught so. How long do you recon it should take?

the_wolf · Jan 26, 2015

toms3 said:
Cheers guys! I thaught so. How long do you recon it should take?

In all honesty I'd give yourself 3 days.

toms3 · Jan 27, 2015

the_wolf said:
In all honesty I'd give yourself 3 days.

Oh dear! What makes it difficult? Removing/replacing parts or manovering it back on?

the_wolf · Jan 27, 2015

toms3 said:
Oh dear! What makes it difficult? Removing/replacing parts or manovering it back on?

Just everything really. The bolts are that inaccessible and most often seized. I would recommend a good set of single hex sockets as they may round easily. Once it's loose you'll need to remove the intercooler, manifold or both to get it out as there is no way you'll get it out with those fitted. I knew what I was doing but the job was that bloody awkward that I had to call in a mobile mechanic to give me a hand (that guy was a life saver. He helped me for 3 solid hours, in the dark and in the ****ing rain and we finally got it free. Only charged me £30 too cos I did most of the work). Anyway, I digress. Just make sure you leave yourself plenty of time. It may come off easy and if it does you're lucky but from experience it's a pig of a job for something so simple.

jamesmartin · Jan 27, 2015

the_wolf said:
Just everything really. The bolts are that inaccessible and most often seized. I would recommend a good set of single hex sockets as they may round easily. Once it's loose you'll need to remove the intercooler, manifold or both to get it out as there is no way you'll get it out with those fitted. I knew what I was doing but the job was that bloody awkward that I had to call in a mobile mechanic to give me a hand (that guy was a life saver. He helped me for 3 solid hours, in the dark and in the ****ing rain and we finally got it free. Only charged me £30 too cos I did most of the work). Anyway, I digress. Just make sure you leave yourself plenty of time. It may come off easy and if it does you're lucky but from experience it's a pig of a job for something so simple.

inter cooler ?piece of **** if you remove manifolds

the_wolf · Jan 27, 2015

That's what I meant, wrong word.

toms3 · Jan 27, 2015

Iv got a week off soon so I'll have to tackle it then, I was stuck in a field after shooting and it would be embarrassing/last resort to get him to tow me to the road! Must have been 5 mins 30 tries before she would turn over, scarey moment! Are they stuck to the engine that makes them hard to remove?

Oldseadog · Jan 27, 2015

Before doing anything else, have you made sure that your earths are sound?

toms3 · Jan 27, 2015

Yes I tried that with a jump lead but no joy

discomania · Jan 27, 2015

toms3 said:
Is there 2 bolts - one either side to undo?

I find the easiest way to do this is to make up about 2/3feet of extension bars and lie under the landy and put the socket on the flange nuts and then carefully crack them all off in one go and once spinning don't stop until it's off as they have a tendency to seize once stopped moving and then when you resume they break the stud as the shaft is now longer and taking more torque.

Refit them with lots of copper slip.

IamRobbie · Jan 27, 2015

I'm sure I removed down pipe of exhaust and then it's just fiddly turning it around with the weight of it to get it to come out

wattfield · Jan 27, 2015

IamRobbie said:
I'm sure I removed down pipe of exhaust and then it's just fiddly turning it around with the weight of it to get it to come out

Me too, but it might be different with the Disco engine. With the downpipe off you can get access to the studs, and can manoeuvre the motor out from above, at least on the Defender engine.

the_wolf · Jan 27, 2015

It is, disco engine sits further back in a Defender and the manifold is in the way. It's impossible to get out without removing the manifold. Trust me, I tried.

wattfield · Jan 27, 2015

the_wolf said:
It is, disco engine sits further back in a Defender and the manifold is in the way. It's impossible to get out without removing the manifold. Trust me, I tried.

Should have bought a proper Defender then, instead of a mongrel!

:behindsofa:

Starter motor change

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