Defender. Manual — part 133
4. Install the engine cover.
5. Install the accessory drive belt.
For additional information, refer to:
Accessory Drive Belt
(303-05 Accessory Drive - 2.4L Duratorq-TDCi HPCR
(103kW/140PS) - Puma, Removal and Installation).
6. Connect the battery ground cable.
For additional information, refer to:
Battery Connect
(414-01
Battery, Mounting and Cables, General Procedures).
Starting System - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma -
Description
Nm
lb-ft
Starter motor bolts
35
26
Starter motor battery positive cable nut
12
9
Starter motor solenoid cable nut
8
6
Fuel line support bracket nut
8
6
Starting System - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma -
Starting System
Description and Operation
COMPONENT LOCATION
OVERVIEW
The starter motor is rated as 2.0 kW and is of conventional design with the motor and drive pinion in line with the
solenoid mounted above. It is of the pre-engaged type and comprises a series wound motor, an overrunning clutch and
an integral solenoid. This starter incorporates a labyrinth in the front end nose casting to help with water management,
sealing and drainage. The solenoid is sealed to stop water ingress and to alleviate cranking failures due to moisture.
The starter solenoid is energised by a signal from the Engine Control Module (ECM) when the ignition switch is moved to
the crank position. When engine cranking is requested, the ECM checks that a valid key code has been received before
granting the crank request. The power for starter operation is supplied on a substantial single cable connected direct
from the battery positive terminal. The cable is connected to the solenoid via a copper threaded stud and secured with a
nut.
The starter motor is located on the rear LH side of the engine block and protrudes through a recess to drive the flywheel
via a ring gear. The motor is secured to the cylinder block by 2 bolts.
Starting System - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma -
Starting System
Diagnosis and Testing
Overview
For information on the operation of the system:
REFER to:
Starting System
(303-06 Starting System - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma, Description
and Operation).
Inspection and Verification
1. 1. Verify the customer concern.
2. 2. Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection Chart
Mechanical
Electrical
Starter motor
Engine (turns freely)
Battery
Fuses
- Fuse link 5, fuse box under seat
- Megafuse
Starter relay
Wiring harness(es)
Damaged, loose or corroded connectors
Ignition switch
Generator
Engine control module (ECM)
3. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.
4. 4. Use the approved diagnostic system or a scan tool to retrieve any diagnostic trouble codes (DTCs) before
moving onto the symptom chart or DTC index.
Make sure that all DTCs are cleared following rectification.
Symptom Chart
Symptom
Possible causes
Action
The engine does
not crank (starter
motor does not
turn)
Battery
Starter relay
- Output circuit:
high resistance
- Output circuit:
short circuit to
power
Invalid key code
received by
immobilizer
Harness/connectors
Starter motor
Ignition switch
Generator
Engine seized
Check the battery condition and state of charge. Check for DTCs
indicating an immobilizer fault. Check the starter motor relay, ignition
switch and generator circuits. Refer to the electrical guides. Check that
the engine turns freely.
The engine does
not crank (starter
motor does turn)
Starter motor
fitment
Starter motor
Flywheel/drive
plate ring gear
Check the starter motor fitment (fasteners tight, starter motor square to
engine, etc.). Check the flywheel/drive plate ring gear teeth for damage,
foreign objects, etc.
Engine cranks too
slowly
Battery
Harness/connectors
Starter motor
Oil grade
Check the battery condition and state of charge. Check the starter motor
circuits. Refer to the electrical guides. Check the engine oil grade and
condition.
Engine cranks too
fast
Low engine
compression
Check the engine condition and compressions.
Excessive starter
motor noise
Starter motor
Flywheel/drive
plate ring gear
Starter motor
Check the starter motor fitment (fasteners tight, motor square to
engine, etc.). Check the starter motor casing condition. Check the
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