1985 BMW 3 SERIES Crank

the bearing - use your fingernail or the edge of
a credit card.
20Make sure the bearing faces are perfectly
clean, then apply a uniform layer of
molybdenum disulphide (“moly”) grease or
engine assembly oil to both of them. You’ll
have to push the piston into the cylinder to
expose the face of the bearing shell in the
connecting rod - be sure to slip the protective
hoses over the rod bolts first, where
applicable.
21Slide the connecting rod back into place
on the journal, and remove the protective
hoses from the rod cap bolts. Refit the rod
cap, and tighten the nuts/bolts to the
specified torque.
22Repeat the entire procedure for the
remaining pistons/connecting rods.
23The important points to remember are:
a) Keep the back sides of the bearing shells
and the insides of the connecting rods
and caps perfectly clean when
assembling them.
b) Make sure you have the correct
piston/rod assembly for each cylinder.
c) The notch or mark on the piston must
face the front of the engine.
d) Lubricate the cylinder walls with clean oil.
e) Lubricate the bearing faces when refitting
the rod caps after the oil clearance has
been checked.
24After all the piston/connecting rod
assemblies have been properly fitted, rotate
the crankshaft a number of times by hand to
check for any obvious binding.25Check the connecting rod side play (see
Section 13).
26Compare the measured side play to the
Specifications to make sure it’s correct. If it
was correct before dismantling, and the
original crankshaft and rods were refitted, it
should still be right. If new rods or a new
crankshaft were fitted, the side play may be
incorrect. If so, the rods will have to be
removed and taken to a machine shop for
attention.
27 Initial start-up and running-
in after overhaul
1
Warning:Have a fire extinguisher
handy when starting the engine
for the first time.
1Once the engine has been refitted in the
vehicle, double-check the engine oil and
coolant levels.
2With the spark plugs removed and the
ignition system disabled (see Section 3), crank
the engine until oil pressure registers on the
gauge, or until the oil pressure warning light
goes out.
3Refit the spark plugs, connect the HT leads,
and restore the ignition system functions (see
Section 3).
4Start the engine. It may take a few
moments for the fuel system to build uppressure, but the engine should start without
a great deal of effort. Note: If backfiring
occurs through the throttle body or
carburettor, check the valve timing (check that
the timing chain/belt has been correctly fitted),
the firing order (check the fitted order of the
spark plug HT leads), and the ignition timing.
5After the engine starts, it should be allowed
to warm up to normal operating temperature.
While the engine is warming up, make a
thorough check for fuel, oil and coolant leaks.
6Shut the engine off and recheck the engine
oil and coolant levels.
7Drive the vehicle to an area with minimum
traffic, accelerate at full throttle from 30 to
50 mph, then lift off the throttle completely,
and allow the vehicle to slow to 30 mph with
the throttle closed. Repeat the procedure
10 or 12 times. This will load the piston rings,
and cause them to seat properly against the
cylinder walls. Check again for oil and coolant
leaks.
8Drive the vehicle gently for the first
500 miles (no sustained high speeds) and
keep a constant check on the oil level. It is not
unusual for an engine to use oil during the
running-in period.
9At approximately 500 to 600 miles, change
the oil and filter.
10For the next few hundred miles, drive the
vehicle normally - don’t nurse it, but don’t
abuse it, either.
11After 2000 miles, change the oil and filter
again. The engine may now be considered to
be fully run-in.
2B•22 General engine overhaul procedures

6Unscrew the four nuts retaining the air
cleaner to the carburettor, and remove the
metal ring (see illustrations).
7Unscrew the nut from the mounting bracket
(see illustration).
8Lift the air cleaner from the carburettor, and
disconnect the crankcase ventilation hose
(see illustration). If necessary, prise the
sealing ring from the bottom of the air cleaner.
9Refitting is a reversal of removal, but align
the arrow on the cover with the arrow on the
inlet tube (see illustration).
Fuel injection engines
10Detach the air intake duct from the front
side of the air cleaner.11Detach the duct between the air cleaner
and the throttle body.
12Remove the air filter (see Chapter 1).
13Unplug the electrical connector from the
airflow meter (see Section 12).
14Remove the air cleaner mounting bolts
(see illustration)and lift the air cleaner
assembly from the engine compartment.
15Refitting is the reverse of removal. Ensure
that all ducts are securely refitted, or air leaks
will result.
9 Accelerator cable- check,
adjustment and renewal
1
Check
1Separate the air intake duct from the
throttle body (fuel injection models) or remove
the air cleaner (carburettor models).
2Have an assistant depress the accelerator
pedal to the floor while you watch the throttle
valve. It should move to the fully-open
position.
3Release the accelerator pedal, and make
sure the throttle valve returns smoothly to the
fully-closed position. The throttle valve should
not contact the body at any time during its
movement; if it does, the unit must be renewed.
Adjustment
4Warm the engine to normal operating
temperature, then switch it off. Depress theaccelerator pedal to the floor twice, then
check the cable free play at the
carburettor/throttle body. Compare it to the
value listed in this Chapter’s Specifications.
5If the free play isn’t as specified, adjust it by
turning the adjustment nut (see illustration).
6Have an assistant help you verify the
throttle valve is fully open when the
accelerator pedal is depressed to the floor.
Renewal
Note:The following paragraphs describe the
procedure for fuel injection engines - the
procedure is similar on carburettor engines
7Disconnect the battery negative cable.
Fuel and exhaust systems 4•9
8.6b . . . and remove the metal ring8.6a Unscrew the four air cleaner-to-
carburettor nuts . . .8.4 Air cleaner inlet duct (1) and warm-air
hose (2)
9.5 To adjust the accelerator cable free
play, hold nut B stationary and turn nut A
(fuel injection engine shown)8.14 Remove the two nuts (arrowed) from
the air cleaner assembly (Motronic system
shown), and lift it off its mountings
8.8 Disconnecting the crankcase
ventilation hose from the air cleaner8.7 Air cleaner mounting bracket nut
(arrowed)8.9 Align the air cleaner cover arrows
when refitting
4

Engine difficult to start, or fails to start (when cold)
Probable cause Corrective action
Cold start injector or thermotime switch
faulty (early Motronic system only) Test cold start injector and thermotime switch. Renew faulty components (see Section 19)
Fuel pump not running Check fuel pump fuse and fuel pump relay (see Sections 2 and 3)
Airflow meter flap (door) binding, or
stuck in open position Inspect the airflow meter for damage (see Section 16)
Fuel pressure incorrect Test system pressure (see Section 3)
Intake air leaks Inspect all vacuum lines, air ducts and oil filler and dipstick seals
Fuel injectors clogged or not operating Check fuel injectors (see Section 20) and wiring harness
Coolant temperature sensor faulty or Test coolant temperature sensor (see Chapter 6, Section 4)
wiring problem
TPS (throttle position sensor) incorrectly adjusted Check TPS adjustment (see Chapter 6, Section 4)
Dirt or other contaminants in fuel Check the fuel and drain the tank if necessary
Faulty ECU Have the ECU tested at a dealer service department or other specialist
Crankshaft position signal missing Faulty position sensor or flywheel, or reference pin missing (see Chapter 5)
Engine difficult to start, or fails to start (when warm)
Probable cause Corrective action
Cold start injector leaking or operating
continuously (early Motronic system only) Test cold start injector and thermotime switch (see Section 19)
Fuel pressure incorrect Test fuel pressure (see Section 3)
Insufficient residual fuel pressure Test fuel system hold pressure (see Section 3)
Fuel leak(s) Inspect fuel lines and fuel injectors for leaks. Correct leaks as necessary
Coolant temperature sensor faulty
or wiring problem Test coolant temperature sensor (see Chapter 6, Section 4)
Vapour lock (in warm weather) Check fuel pressure (see Section 3)
EVAP system faulty Check EVAP system (see Chapter 6, Section 6)
Faulty ECU Have the ECU tested at a dealer service department or other specialist
Idle speed control system faulty Test the idle air stabiliser valve (see Section 21)
Oxygen sensor faulty (where applicable) Check the oxygen sensor (see Chapter 6, Section 4)
Engine misses and hesitates under load
Probable cause Corrective action
Fuel injector clogged Test fuel injectors. Check for clogged injector lines. Renew faulty injectors (see Section 20)
Fuel pressure incorrect Test fuel system pressure (see Section 3). Test fuel pressure regulator (see Section 18)
Fuel leak(s) Inspect fuel lines and fuel injectors for leaks (see Chapter 4)
Engine maintenance Tune-up engine (see Chapter 1). Check the distributor cap, rotor, HT leads and spark
plugs, and renew any faulty components
Airflow meter flap (door) binding, or Inspect the airflow meter for damage (see Section 16)
stuck in open position
Intake air leaks Inspect all vacuum lines, air ducts, and oil filler and dipstick seals
Throttle position sensor (TPS) incorrectly adjusted Check TPS adjustment (see Chapter 6)
Engine idles too fast
Probable cause Corrective action
Accelerator pedal, cable or throttle valve binding Check for worn or broken components, kinked cable, or other damage. Renew faulty
components
Air leaking past throttle valve Inspect throttle valve, and adjust or renew as required
Engine has erratic idle speed
Probable cause Corrective action
Idle air stabiliser valve faulty Check the idle air stabiliser valve (see Section 21)
No power to the idle air stabiliser valve Check the idle air stabiliser relay and wiring circuit (see Chapter 12)
Idle speed control unit faulty Have the idle speed control unit checked by a dealer
Poor fuel economy
Probable cause Corrective action
Cold start injector leaking
(early Motronic system only) Test and, if necessary, renew cold start injector (see Section 19)
Oxygen sensor faulty (where applicable) Test the oxygen sensor (see Chapter 6, Section 4))
Sticking handbrake/binding brakes Check the handbrake/braking system (see Chapter 9)
Tyre pressures low Check tyre pressures (Chapter 1)
4•22 Fuel and exhaust systems

1 General information
The engine electrical systems include all
ignition, charging and starting components.
Because of their engine-related functions,
these components are discussed separately
from body-related electrical devices such as
the lights, the instruments, etc. (which are
included in Chapter 12).
Always observe the following precautions
when working on the electrical systems:
a) Be extremely careful when servicing
engine electrical components. They are
easily damaged if improperly checked,
connected or handled.
b) Never leave the ignition switched on for
long periods of time with the engine off.
c) Don’t disconnect the battery cables while
the engine is running.
d) Observe the rules when jump-starting
your vehicle. Read the precautions at the
front of this manual.
e) Always disconnect the battery negative
cable first, and connect it last, to reduce
the risk of accidental short-circuits.
f) Don’t charge the battery with the cables
connected to the terminals.
It’s also a good idea to review the safety-
related information regarding the engine
electrical systems in the “Safety first”section
near the front of this manual before beginning
any operation included in this Chapter.
Caution: If the radio in your
vehicle is equipped with an anti-
theft system, make sure you
have the correct activation code
before disconnecting the battery. Refer to
the information on page 0-7 at the front of
this manual before detaching the cable.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.
2 Battery-
emergency jump starting
1
Refer to the “Jump starting”procedure at
the front of this manual.
3 Battery- removal and refitting
1
Note:Depending on the model, the battery
may be located in the engine compartment, in
the rear luggage compartment, or under the
rear seat. Consult your owners handbook for
the location of the battery, if not already
known to you.Caution: If the radio in your
vehicle is equipped with an anti-
theft system, make sure you
have the correct activation code
before disconnecting the battery. Refer to
the information on page 0-7 at the front of
this manual before detaching the cable.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.
1Disconnect the battery negative cable.
2Detach the cable from the positive terminal.
3Remove the battery hold-down bracket
(see illustrations)and lift out the battery. Be
careful - it’s heavy. Do not tilt the battery to
any extent while it is being removed, and
store it upright.
4While the battery is out, inspect the carrier
(tray) for corrosion (see Chapter 1).
5If you are renewing the battery, make sure
that you get one that’s identical, with the
same dimensions, amperage rating, cold
cranking rating, etc.
6Refitting is the reverse of removal.
4 Battery cables-
check and renewal
1
Check
1Periodically inspect the entire length of
each battery cable for damage, cracked or
burned insulation, and corrosion.
Poor battery cable connections can cause
starting problems and decreased engine
performance.
Caution: If the radio in your
vehicle is equipped with an anti-
theft system, make sure you
have the correct activation code
before disconnecting the battery. Refer to
the information on page 0-7 at the front of
this manual before detaching the cable.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.2Check the cable-to-terminal connections at
the ends of the cables for cracks, loose wire
strands, and corrosion. The presence of
white, fluffy deposits under the insulation at
the cable terminal connection is a sign that
the cable is corroded, and should be cleaned
or renewed. Check the terminals for
distortion, missing mounting bolts, and
corrosion.
Renewal
3When removing the cables, always
disconnect the negative cable first and
connect it up last. This reduces the risk of
accidental short-circuits. Even if only a new
positive cable is being fitted, be sure to
disconnect the negative cable from the
battery first (see Chapter 1 for further
information regarding battery cable removal).
4Disconnect the old cables from the battery,
then trace each of them to their opposite ends
and detach them from the starter solenoid
and earth terminals. Note the routing of each
cable to ensure correct refitting.
5If the old cables are to be renewed, take
them with you when buying new cables. It is
vitally important that you renew the cables
with identical parts. Cables have character-
istics that make them easy to identify: positive
cables are usually red, larger in cross-section,
and have a larger-diameter battery post
clamp; earth cables are usually black, smaller
in cross-section, and have a slightly smaller
diameter clamp for the negative post.
6Clean the threads of the solenoid or earth
connection with a wire brush to remove rust
and corrosion.
7Attach the cable to the solenoid or earth
connection, and tighten the mounting nut/bolt
securely.
8Before connecting a new cable to the
battery, make sure that it reaches the battery
post without having to be stretched.
9Connect the positive cable first, followed by
the negative cable.
5•2 Engine electrical systems
3.3b The battery is mounted under the
rear seat on some models
3.3a Always detach the cable from the
battery negative terminal first, then detach
the positive cable – to remove the hold-
down assembly, remove the nuts (arrowed)
or single bolt
Apply a light coat of battery
terminal corrosion inhibitor,
or petroleum jelly, to the
terminal threads, to prevent
future corrosion.

5 Ignition system- general
information and precautions
The ignition system includes the ignition
switch, the battery, the distributor, the primary
(low-voltage/low-tension or LT) and
secondary (high-voltage/high-tension or HT)
wiring circuits, the spark plugs and the spark
plug leads. Models fitted with a carburettor or
L-Jetronic fuel injection are equipped with a
Transistorised Coil Ignition (TCI) system.
Models fitted with the Motronic fuel injection
system have the ignition system incorporated
within the Motronic system (Digital Motor
Electronics or DME).
Transistorised Coil Ignition (TCI)
system
This system is has four major components;
the impulse generator, the ignition control
unit, the coil, and the spark plugs. The
impulse generator provides a timing signal for
the ignition system. Equivalent to cam-
actuated breaker points in a standard
distributor, the impulse generator creates an
A/C voltage signal every time the trigger
wheel tabs pass the impulse generator tabs.
When the ignition control unit (capacitive
discharge unit) receives the voltage signal, it
triggers a spark discharge from the coil by
interrupting the primary coil circuit. The
ignition dwell (coil charging time) is adjusted
by the ignition control unit for the most
intense spark. Note: The air gap (distance
between the impulse generator and trigger
wheel tabs) can be adjusted (see Section 11).
Ignition timing is mechanically adjusted
(see Section 7). A centrifugal advance unit
that consists of spring-loaded rotating
weights advances ignition timing as engine
speed increases. The vacuum advance
adjusts ignition timing to compensate for
changes in engine load.
Motronic ignition system
This system, also known as Digital Motor
Electronics (DME), incorporates all ignition
and fuel injection functions into one central
control unit or ECU (computer). The ignition
timing is based on inputs the ECU receives for
engine load, engine speed, coolant
temperature and intake air temperature. The
only function the distributor performs is the
distribution of the high voltage signal to the
individual spark plugs. The distributor is
attached directly to the cylinder head. There is
no mechanical spark advance system used on
these systems.
Ignition timing is electronically-controlled,
and is not adjustable on Motronic systems.
During starting, a crankshaft position sensor
(reference sensor) relays the crankshaft
position to the ECU, and an initial baseline
ignition point is determined. Once the engineis running, the ignition timing is continually
changing, based on the various input signals
to the ECU. Engine speed is signalled by a
speed sensor. Early Motronic systems have
the position reference sensor and the speed
sensor mounted on the bellhousing over the
flywheel on the left-hand side. Later Motronic
systems have a single sensor (pulse sensor)
mounted over the crankshaft pulley. This
sensor functions as a speed sensor as well as
a position reference sensor. Refer to Sec-
tion 12 for checking and renewing the ignition
sensors. Note: Some models are equipped
with a TDC sensor mounted on the front of the
engine. This sensor is strictly for the BMW
service test unit, and it is not part of the
Motronic ignition system.
Precautions
Certain precautions must be observed
when working on a transistorised ignition
system.
a) Do not disconnect the battery cables
when the engine is running
b) Make sure the ignition control unit (TCI
ignition system) is always well earthed
(see Section 10).
c) Keep water away from the distributor and
HT leads.
d) If a tachometer is to be connected to the
engine, always connect the tachometer
positive (+) lead to the ignition coil
negative terminal (-) and never to the
distributor.
e) Do not allow the coil terminals to be
earthed, as the impulse generator or coil
could be damaged.
f) Do not leave the ignition switch on for
more than ten minutes with the engine
off, or if the engine will not start.
6 Ignition system- check
2
Warning: Because of the high
voltage generated by the ignition
system, extreme care should be
taken whenever an operation is
performed involving ignition components.
This not only includes the impulse
generator (electronic ignition), coil,
distributor and spark plug HT leads, but
related components such as spark plug
connectors, tachometer and other test
equipment.
1If the engine turns over but will not start,
disconnect the spark plug HT lead from any
spark plug, and attach it to a calibrated spark
tester (available at most car accessory
shops).
Note:There are two different types of spark
testers. Be sure to specify electronic
(breakerless) ignition. Connect the clip on thetester to an earth point such as a metal
bracket (see illustration).
2If you are unable to obtain a calibrated
spark tester, remove the spark plug HT lead
from one of the spark plugs. Using an
insulated tool, hold the lead about a quarter-
inch from the engine block - make sure the
gap is not more than a quarter-inch, or
damage may be caused to the electronic
components.
3Crank the engine, and observe the tip of the
tester or spark plug HT lead to see if a spark
occurs. If bright-blue, well-defined sparks
occur, sufficient voltage is reaching the plugs
to fire the engine. However, the plugs
themselves may be fouled, so remove and
check them as described in Chapter 1.
4If there’s no spark, check another HT lead
in the same manner. A few sparks followed by
no spark is the same condition as no spark at
all.
5If no spark occurs, remove the distributor
cap, and check the cap and rotor as
described in Chapter 1. If moisture is present,
use a water-dispersant aerosol (or something
similar) to dry out the cap and rotor, then refit
the cap and repeat the spark test.
6If there’s still no spark, disconnect the coil
HT lead from the distributor cap, and
test this lead as described for the spark plug
leads.
7If no spark occurs, check the primary wire
connections at the coil to make sure they’re
clean and tight. Make any necessary repairs,
then repeat the check.
8If sparks do occur from the coil HT lead, the
distributor cap, rotor, plug HT lead(s) or spark
plug(s) may be defective. If there’s still no
spark, the coil-to-cap HT lead may be
defective. If a substitute lead doesn’t make
any difference, check the ignition coil (see
Section 9). Note:Refer to Sections 10 and 11
for more test procedures on the distributors
fitted with the TCI ignition system.
Engine electrical systems 5•3
6.1 To use a spark tester, simply
disconnect a spark plug HT lead, clip the
tester to a convenient earth (like a valve
cover bolt or nut) and operate the starter –
if there is enough power to fire the plug,
sparks will be visible between the
electrode tip and the tester body
5

8Use a digital voltmeter for the following
tests:
a) On Bosch systems, connect the positive
probe to connector terminal 5, and the
negative probe to terminal 6 (see
illustration).
b) On Siemens/Telefunken systems, connect
the positive probe to terminal (+) of the
smaller connector, and the negative
probe to terminal (-).
9Have an assistant crank the engine over,
and check that there is 1 to 2 volts A/C
present. If there is no voltage, check the
wiring harness between the impulse generator
(in the distributor) and the control unit. If the
harness is OK, check the impulse generator
resistance.
Warning: Do not crank the
engine over for an excessive
length of time. If necessary,
disconnect the cold start injector
electrical connector (see Chapter 4) to
stop the flow of fuel into the engine.
10To check the resistance in the impulse
generator, proceed as described for your
system below:
a) On Bosch units, measure the resistance
between connector terminals 5 and 6
(see illustration 10.8). The reading
should be 1000 to 1200 ohms.
b) On Siemens/Telefunken units, measure
the resistance between the terminals of
the smaller connector. The reading should
be 1000 to 1200 ohms.
11If the resistance readings are incorrect,
renew the impulse generator. If the resistance
readings for the impulse generator are correct
and the control unit voltages (supply voltage
[paragraphs 1 to 6] and signal voltage
[paragraphs 7 to 9]) are incorrect, renew the
control unit.
Renewal
Ignition control unit
12Make sure the ignition is switched off.
13Disconnect the electrical connector(s)
from the control unit.
14Remove the mounting screws from the
control unit, and lift it from the engine
compartment.15Refitting is the reverse of removal. Note:
On Bosch control units, a special dielectric
grease is used between the heat sink and the
back of the control unit. In the event the two
are separated (renewal or testing) the old
grease must be removed, and the heat sink
cleaned off using 180-grit sandpaper. Apply
Curil K2 (Bosch part number 81 22 9 243). A
silicon dielectric compound can be used as a
substitute. This treatment is very important for
the long life of these expensive ignition parts.
Impulse generator
Caution: If the radio in your
vehicle is equipped with an anti-
theft system, make sure you
have the correct activation code
before disconnecting the battery. Refer to
the information on page 0-7 at the front of
this manual before detaching the cable.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.
16Disconnect the battery negative cable.
17Remove the distributor from the engine
(see Section 8).
18Using a pair of circlip pliers, remove the
circlip retaining the trigger wheel (see
illustration).
19Use two flat-bladed screwdrivers
positioned at opposite sides of the trigger
wheel, and carefully prise it up (see
illustration). Note: Push the screwdrivers in
as far as possible without bending the trigger
wheel. Prise only on the strongest, centre
portion of the trigger wheel. In the event the
trigger wheel is bent, it must be replaced with
a new one. Note:Be sure not to lose the roll
pin when lifting out the trigger wheel.
20Remove the mounting screws from the
impulse generator electrical connector, the
vacuum diaphragm and the baseplate.
21Remove the two screws from the vacuum
advance unit, and separate it from the
distributor by moving the assembly down
while unhooking it from the baseplate pin.
22Use circlip pliers to remove the circlip that
retains the impulse generator and the
baseplate assembly.
23Carefully remove the impulse generator
and the baseplate assembly as a single unit.24Remove the three screws, and separate
the baseplate assembly from the impulse
generator.
25Refitting is the reverse of removal. Note:
Be sure to position the insulating ring between
the generator coil and the baseplate. It must
be centred before tightening the mounting
screws. Also, it will be necessary to
check/adjust the air gap if the trigger wheel
has been removed, or tampered with to the
point that the clearance is incorrect (see
Section 11).
11 Air gap (TCI system)-
check and adjustment
2
Caution: If the radio in your
vehicle is equipped with an anti-
theft system, make sure you
have the correct activation code
before disconnecting the battery. Refer to
the information on page 0-7 at the front of
this manual before detaching the cable.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.
1Disconnect the battery negative cable.
2Insert a brass feeler gauge between the
trigger wheel tab and the impulse generator
(see illustration). Slide the feeler gauge up
Engine electrical systems 5•7
10.19 Carefully prise the trigger wheel off
the distributor shaft10.18 Use circlip pliers and remove the
circlip from the distributor shaft10.8 Back-probe the ignition control unit
connector, and check for signal voltage on
terminals 5 and 6 (Bosch system shown). It
is very helpful to use angled probes
11.2 Use a brass feeler gauge to check
the air gap (be sure the gauge rubs lightly
against the trigger wheel as well as the
locating pin for the correct adjustment)
5

Refer to the information on page 0-7 at the
front of this manual before detaching the
cable.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.
1Disconnect the battery negative cable.
Bosch alternator
2Remove the voltage regulator from the back
of the alternator (see Section 16).
3Measure the length of the brushes (see
illustration). They should not be less than
6.0 mm. If any are worn past this point, renew
them all as a set. 4Also check for excessively worn slip rings
(see illustration 16.5).
5The brushes are retained either by set
screws or by solder. If you are not skilled at
soldering, it may be best to have an auto
electrician fit the new brushes. Note: Be
careful not to apply heat to the solder joint for
more than 5 seconds. If necessary, use a heat
sink to capture the excess heat. This can be
accomplished by clamping a pair of needle-
nose pliers next to the solder joint.
6On the screw type, hold the assembly in
place and refit the screws. Tighten them
evenly, a little at a time, so the holder isn’t
distorted.
7Refit the regulator assembly to the
alternator.8Reconnect the battery negative cable.
Motorola alternator
9Remove the alternator.
10The brushes are mounted under the
regulator on the rear of the alternator (see
illustration 16.7).
11Remove the mounting screws and
insulating washers, and separate the voltage
regulator and brush holder from the brush end
housing.
12Measure the length of the brushes (see
illustration 17.3). If any brush is less then
6.0 mm long, renew them all as a set.
13Make sure the brushes move smoothly in
the holder.
14Refit the brush holder/regulator. Tighten
the screws securely. Make sure the brushes
aren’t earthed.
15Refitting is the reverse of removal.
18 Starting system- general
information and precautions
The sole function of the starting system is
to turn over the engine quickly enough to
allow it to start.
The starting system consists of the battery,
the starter motor, the starter solenoid, the
ignition switch, and the wires connecting
them. The solenoid is mounted directly on the
starter motor. The starter/solenoid motor
assembly is fitted on the lower part of the
engine, next to the transmission bellhousing.
When the ignition key is turned to the Start
position, the starter solenoid is actuated
through the starter control circuit. The starter
solenoid then connects the battery to the
starter, and moves the starter pinion into
mesh with the flywheel ring gear. The battery
supplies the electrical energy to the starter
motor, which does the actual work of cranking
the engine.
The starter motor on some manual
transmission vehicles can only be operated
when the clutch pedal is depressed. On a
vehicle equipped with automatic
transmission, the starter can only be operated
Engine electrical systems 5•11
17.3 Check the brush length in the normal
rest position (spring uncoiled)
5
16.7 Exploded view of the Motorola alternator

when the transmission selector lever is in Park
or Neutral.
Always detach the battery negative cable
before working on the starting system.
19 Starter motor-
in-vehicle check
2
Note:Before diagnosing starter problems,
make sure the battery is fully charged.
1If the starter motor does not turn at all when
the switch is operated, make sure that the
gear lever is in Neutral or Park (automatic
transmission) or, where applicable, that the
clutch pedal is depressed (manual
transmission).
2Make sure that the battery is charged, and
that all cables, both at the battery and starter
solenoid terminals, are clean and secure.
3If the starter motor spins but the engine is
not cranking, the overrun clutch in the starter
motor is slipping, and the starter motor must
be renewed.
4If, when the switch is actuated, the starter
motor does not operate at all but the solenoid
clicks, then the problem lies either in the
battery, the main solenoid contacts, or the
starter motor itself (or the engine is seized).
5If the solenoid plunger cannot be heard
when the switch is actuated, the battery is
faulty, the switch is defective, the fusible link
is burned-out (the circuit is open), or the
solenoid itself is defective.
6To check the solenoid, connect a jumper
lead between the battery (+) and the ignition
switch wire terminal (the small terminal) on the
solenoid. If the starter motor now operates,
the solenoid is OK and the problem is in the
ignition switch, starter inhibitor switch
(automatic transmission models), clutch
switch (some manual transmission models), or
the wiring.
7If the starter motor still does not operate,
remove the starter/solenoid assembly for
dismantling, testing and repair.
8If the starter motor cranks the engine at an
abnormally-slow speed, first make sure that
the battery is charged, and that all terminal
connections are tight. If the engine is partially-
seized, or has the wrong viscosity oil in it, it
will crank slowly.
9Run the engine until normal operating
temperature is reached, then disconnect the
coil HT lead from the distributor cap and earth
it on the engine.
10Connect a voltmeter positive lead to the
battery positive post, and connect the
negative lead to the negative post.11Crank the engine, and take the voltmeter
readings as soon as a steady figure is
indicated. Do not allow the starter motor to
turn for more than 10 seconds at a time. A
reading of 9 volts or more, with the starter
motor turning at normal cranking speed, is
normal. If the reading is 9 volts or more but
the cranking speed is slow, the solenoid
contacts are burned, there is a bad
connection, or the starter motor itself is faulty.
If the reading is less than 9 volts and the
cranking speed is slow, the starter motor is
faulty or the battery is responsible (defective
or discharged).
20 Starter motor-
removal and refitting
1
Note:If the starter motor is defective, it should
be renewed, or taken to an auto electrical
specialist for repair. Overhaul of the starter
motor is unlikely to be a practical proposition
for the home mechanic, even if spare parts are
available. However, the solenoid can be
renewed separately (see Section 21).
Removal
Caution: If the radio in your
vehicle is equipped with an anti-
theft system, make sure you
have the correct activation code
before disconnecting the battery. Refer to
the information on page 0-7 at the front of
this manual before detaching the cable.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.
1Detach the battery negative cable.
2Raise the vehicle and support it securely on
axle stands.
3Clearly label the wires from the terminals onthe starter motor and solenoid, then
disconnect them. Note: On some models, it
may be necessary to remove the air cleaner
(see Chapter 4), coolant expansion tank (see
Chapter 3) and the heater hoses to gain
access to the top of the starter. Carefully label
any hoses or components that need to be
removed from the engine compartment, to
avoid confusion when reassembling.
4Unscrew the mounting bolts and detach the
starter (see illustrations).
Refitting
5Refitting is the reverse of removal.
21 Starter solenoid-
removal and refitting
1
Removal
Caution: If the radio in your
vehicle is equipped with an anti-
theft system, make sure you
have the correct activation code
before disconnecting the battery. Refer to
the information on page 0-7 at the front of
this manual before detaching the cable.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.
1Disconnect the battery negative cable.
2Remove the starter motor (see Section 20).
3Disconnect the cable from the solenoid to
the starter motor terminal.
4Remove the screws which secure the
solenoid to the starter motor.
5Detach the solenoid from the starter body.
6Remove the plunger and plunger spring.
Refitting
7Refitting is the reverse of removal.
5•12 Engine electrical systems
20.4b Withdrawing the starter motor from
the M40 engine20.4a Working under the vehicle, remove
the starter lower mounting bolt and nut
(arrowed)