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Dodgy starter motor solenoid on L-series Freelander, TD4, TD5 or K V6

Discussion in 'Common Faults and Questions' started by Spacemonkey..., Feb 22, 2011.

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  1. Spacemonkey...

    Spacemonkey... Well-Known Member

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    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..

    [​IMG]

    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:

    [​IMG]

    [​IMG]

    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:

    [​IMG]

    [​IMG]

    [​IMG]

    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.

    [​IMG]

    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)

    [​IMG]

    And drop in the plunger, remembering to transfer the spring across, and I also added a little lubricant grease:

    [​IMG]

    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:

    [​IMG]
     
    Hippo likes this.
  2. ebb3005

    ebb3005 New Member

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    Thanks Spacemonkey,
    My 98 Freelander wouldn't start last wednesday, same symptoms as you experienced. ordered the kit through ebay on wed arrived thurs morning fixed thurs afternoon cost me £12 including postage. That bottom bolt proved a bit of a bugger to get out but other than that dead easy.

    Thanks again saved me a packet.
     
  3. Spacemonkey...

    Spacemonkey... Well-Known Member

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    No problems!!! Glad to help :)

    Mine has worked perfectly the last 10k miles since I posted this.

    Gotta sell mine now as I bought a soft top Pajero.. :D
     
    Last edited: Sep 10, 2011
  4. Moggz

    Moggz New Member

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    After being quoted £400+ to repair the starter motor, I found this thread!

    Thankyou so much Spacemonkey, you are now my hero!

    It took me a while to get the motor out, that back bolt is not easy to work on! But your instructions were perfect. So a tenner for parts and a few hours work and I now have a Vroomy Beastie again!

    It was also priceless to see the faces of passers by when they realised a girl was removing/repairing/refitting the SM on her car!
     
  5. Spacemonkey...

    Spacemonkey... Well-Known Member

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    Glad to help, and it's always nice to see a girl working on their own car. You get a thumbs up from me! :cool:
     
  6. merlin617

    merlin617 New Member

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    Spacemonkey I just registered here to thank you for putting up such detailed pictures for the removal of the L series starter motor. I have a Rover 220 SD and could not free the stater motor to carry out that repair. Now I can see the bolt I need to remove but missed.

    One day I'll have a landy:)
     
  7. Spacemonkey...

    Spacemonkey... Well-Known Member

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    Thanks mate! Nice to know it's been of use. A Rover, then a Landy? You must like punishment... ;)
     
  8. zzr1200

    zzr1200 Well-Known Member

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    :nopics:

    please post piccy of yourself....;)
     
  9. plantjes

    plantjes New Member

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    Got also the dodgy solenoid...
    Took out the startmotor and cleaned/polished the contacts..
    Works like a charm, but made a mistake...
    When bolting back together i caught some wires underneath the startmotor causing a short and broken wires..
    Took me almost 5 days checking and surging to get it back in working order...

    Some pict...
    http://i300.photobucket.com/albums/nn36/plantjes/modelbouw/20140213_104306.jpg
    http://i300.photobucket.com/albums/nn36/plantjes/modelbouw/20140213_104329.jpg

    Check that my startmotor has 3 mounting bolts..

    http://i300.photobucket.com/albums/nn36/plantjes/modelbouw/20140213_104314.jpg

    and the problem...

    http://i300.photobucket.com/albums/nn36/plantjes/modelbouw/20140216_100925.jpg

    http://i300.photobucket.com/albums/nn36/plantjes/Mobile Uploads/20140217_161957.jpg

    So the conclusion...
    different models have different parts (yes offcause)
    Be careful what you start, you may end up creating more problems...

    But my 200 euro repair (checked at local dealer) was 0 euro and some free time...

    Benno
     
  10. BL4CK0P3R4T1V3

    BL4CK0P3R4T1V3 New Member

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    Thankyou!! Saved me a few much need £££'s that did!! A few choice words along the way trying to get the motor off (locating bottom bolt) but alls good now!!!
    Nice one!!!!
     
  11. tonyt37

    tonyt37 Active Member

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    Did this yesterday. Used the repairkitsuk kit. It was spot on.

    Glad I got this as some others don't include the plunger stating that it is not needed and will just need cleaning. I wouldn't like to rely on getting a good connection by just cleaning my old plunger. It was knackered completely. Make sure you choose a kit with plunger.
     
  12. variotomatonini

    variotomatonini New Member

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    nice one!! mines been driving me crazy.just got some money for starter and found this thread while looking at prices.all ordered for tuesday. cheers
     
  13. Sparrow36

    Sparrow36 Member

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    I knew I'd find my answer here! Mine is doing the same, my bro seems to think that as its at the front it gets full of cack as well. My husband did it last time (a year or so ago) but I really want to do it myself this time. Will keep this thread handy
     
  14. barrie james

    barrie james New Member

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    Hi guys,
    i need to change the starter motor but im struggling with the bottom bolt, any suggestions on how to get the bugger out
     
  15. neilly

    neilly Well-Known Member

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    @barrie james

    May help if you say what motor and engine????

    Cheersp
     
  16. The Mad Hat Man

    The Mad Hat Man Well-Known Member LZIR Despatch Agent

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    Patience
     
  17. JUKE179r

    JUKE179r Active Member

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    Great info and pics!
    I can probably apply this to my Disco 2 V8 starter solenoid. It's on my list of things to do.
     
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