Spacemonkey...
Well-Known Member
Had problems starting my 99 model L series Freelander. Was advised it could be the solenoid contacts.
Symptoms include:
Failure of starter to turn- just click once then nothing.
Starter turns only a few revs then stops then nothing.
Occasionally starts but sounds/feels sluggich while turning over- would suspect dodgy battery but everything else seems fine...
Found repair kits available for the Nippn Denso starter fitted to L series, TD5, TD4 and K V6s from Kit Details - RepairkitsUK | Starter Motor Repair Kits | Don't Buy a New Start Motor - Repair It
The kit arrived with clear instructions as on the website, but to be honest, it is a very straightforward operation, and quite obvious.
First remove the airbox by removing two 8mm screws from the battery tray and unclipping the MAF part. The Haynes Book Of Lies says you need to remove the battery and disconnect it. Not so, but work with caution..
The starter motor must be removed, but on the L series this is simple. First remove the main live wire to the solenoid, but take great care to keep it covered by it's rubber piece. In practice this proves quite easy to do, then remove the small solenoid wire which just pulls off its spade end connector. next remove the support bracket and the upper bolt, which are easily visible. Then reach down behind and below the motor to find the lower bolt, both are 15mm IIRC. This pic shows the positional relationship of the two bolts for the motor and I have tried to position the motor in it's correct plane:
Once out, remove the big wire from it's bolt, and also remove the top cap and it's rubber seal, by it's 3 8mm bolts, then remove the solenoid plunger:
The pitting of the copper contacts is what causes the problem. Compare these with new ones and you can see that this is a common design problem. I would strongly suggest anyone with a Nippon Denso starter motor (TD5, TD4, L series, K V6) to routinely replace these contacts and plunger every 100k miles.
The instructions advise fitting only one side at a time to avoid confusion, but I found it simple enough, just remember the order that bits on the bolt come off. The main feed side also has a large bent rectangular plastic 'washer' whilst the other side has rubber gaskets. I cleaned the inside with a little brake cleaner from an aerosol can before refitting, and also rubbed clean the contacts everywhere with scotch cloth (kitchen scourer)
And drop in the plunger, remembering to transfer the spring across, and I also added a little lubricant grease:
It was then a simple case of reassembly is reverse of disassembly in true Haynes fictional style...
Then, insert ignition key, await glow plug light extinction, then turn away.. mine fired up instantly, and has continued every since. Gone is the normal deathly click followed by nothing, or the occasional slight turn of the starter followed by nothing. Simple fix, costing £10 and took me less than an hour, mainly because of taking photos and my usual habit of cleaning everything up as I strip them.
Tools used for the job:
Symptoms include:
Failure of starter to turn- just click once then nothing.
Starter turns only a few revs then stops then nothing.
Occasionally starts but sounds/feels sluggich while turning over- would suspect dodgy battery but everything else seems fine...
Found repair kits available for the Nippn Denso starter fitted to L series, TD5, TD4 and K V6s from Kit Details - RepairkitsUK | Starter Motor Repair Kits | Don't Buy a New Start Motor - Repair It
The kit arrived with clear instructions as on the website, but to be honest, it is a very straightforward operation, and quite obvious.
First remove the airbox by removing two 8mm screws from the battery tray and unclipping the MAF part. The Haynes Book Of Lies says you need to remove the battery and disconnect it. Not so, but work with caution..
The starter motor must be removed, but on the L series this is simple. First remove the main live wire to the solenoid, but take great care to keep it covered by it's rubber piece. In practice this proves quite easy to do, then remove the small solenoid wire which just pulls off its spade end connector. next remove the support bracket and the upper bolt, which are easily visible. Then reach down behind and below the motor to find the lower bolt, both are 15mm IIRC. This pic shows the positional relationship of the two bolts for the motor and I have tried to position the motor in it's correct plane:
Once out, remove the big wire from it's bolt, and also remove the top cap and it's rubber seal, by it's 3 8mm bolts, then remove the solenoid plunger:
The pitting of the copper contacts is what causes the problem. Compare these with new ones and you can see that this is a common design problem. I would strongly suggest anyone with a Nippon Denso starter motor (TD5, TD4, L series, K V6) to routinely replace these contacts and plunger every 100k miles.
The instructions advise fitting only one side at a time to avoid confusion, but I found it simple enough, just remember the order that bits on the bolt come off. The main feed side also has a large bent rectangular plastic 'washer' whilst the other side has rubber gaskets. I cleaned the inside with a little brake cleaner from an aerosol can before refitting, and also rubbed clean the contacts everywhere with scotch cloth (kitchen scourer)
And drop in the plunger, remembering to transfer the spring across, and I also added a little lubricant grease:
It was then a simple case of reassembly is reverse of disassembly in true Haynes fictional style...
Then, insert ignition key, await glow plug light extinction, then turn away.. mine fired up instantly, and has continued every since. Gone is the normal deathly click followed by nothing, or the occasional slight turn of the starter followed by nothing. Simple fix, costing £10 and took me less than an hour, mainly because of taking photos and my usual habit of cleaning everything up as I strip them.
Tools used for the job:
