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BrickBox



Member Since: 05 Oct 2021
Location: Wales
Posts: 606

Wales 2008 Defender 110 Puma 2.4 USW Zermatt Silver
Starter motor removal. 2.4 TDCi
Evening all,

After picking up a new starter motor and popping the bonnet on my 110. I’ve just scratched my head and closed the bonnet as I couldn’t decide which way is best to replace the starter, from underneath or above?

I don’t have the luxury of a ramp, so lying underneath looked a pig of a job, likewise, going from the top and removing coolant hoses also looks a pig of a job.

Any advice, pleaaaaase? 2008 2.4 110 Utility XS.


Last edited by BrickBox on 12th Sep 2022 1:59pm. Edited 1 time in total
Post #964510 9th Sep 2022 4:24pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 16809

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
I think the popular view is that the best way is to get someone else to do it! It is not a pleasant job.

That being said I think sneaking up on it from underneath is the best approach.

It is unfortunately a job of legend due to the poor access, and I suspect that the job becomes easier if you remove the n/s front wing!
Post #964516 9th Sep 2022 5:19pm
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BrickBox



Member Since: 05 Oct 2021
Location: Wales
Posts: 606

Wales 2008 Defender 110 Puma 2.4 USW Zermatt Silver
Thank you for your words of wisodom lol Shocked

It looks as though the easiest way to get to it is plenty of patience and removing the coolant hoses. 2008 2.4 110 Utility XS.
Post #964522 9th Sep 2022 6:29pm
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jst



Member Since: 14 Jan 2008
Location: Taunton
Posts: 7664

2011 Defender 110 Puma 2.4 USW Stornoway Grey
With a patient approach it's actually OK. I haven't done 9ne for two years or so now but had a spate of do8ng several at one point. Getting the ma8n feed 9n I believe was a problem. Approach from below, no need to remove any coolant pipes. Cheers

James
110 XS Utility
130 Puma Station wagon/camper (in the making)
90 Puma Hardtop
Post #964524 9th Sep 2022 6:50pm
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BrickBox



Member Since: 05 Oct 2021
Location: Wales
Posts: 606

Wales 2008 Defender 110 Puma 2.4 USW Zermatt Silver
Cheers for the heads up. I’ll take a look with a full day free ahead. 2008 2.4 110 Utility XS.
Post #964529 9th Sep 2022 7:32pm
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BrickBox



Member Since: 05 Oct 2021
Location: Wales
Posts: 606

Wales 2008 Defender 110 Puma 2.4 USW Zermatt Silver
Off to get a Haynes manual from Halfrauds. Anything for a bit of guidance.. 2008 2.4 110 Utility XS.
Post #964547 10th Sep 2022 7:46am
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Balvaig



Member Since: 19 Feb 2016
Location: Fife
Posts: 719

Scotland 2016 Defender 90 Puma 2.2 Landmark LE Corris Grey
There is a link somewhere on this site to the workshop manual, which may also help.
Post #964551 10th Sep 2022 8:30am
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Ianh



Member Since: 17 Sep 2018
Location: Essex
Posts: 1695

United Kingdom 
Workshop manual https://onedrive.live.com/?authkey=%21ALkd...9C85C7C171

Curtesy of member dgardel Thumbs Up

Plus read this topic for a guide, note blackwolfs comment on using 1/2 inch / 13mm deep socket. https://www.defender2.net/forum/topic29850...p;start=15
Post #964568 10th Sep 2022 12:41pm
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BrickBox



Member Since: 05 Oct 2021
Location: Wales
Posts: 606

Wales 2008 Defender 110 Puma 2.4 USW Zermatt Silver
Excuse my stupidity, but I’ve been through the files and cannot find any guide for the starter motor Confused

All I can find is an index in foreign language.. 2008 2.4 110 Utility XS.
Post #964581 10th Sep 2022 4:23pm
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BrickBox



Member Since: 05 Oct 2021
Location: Wales
Posts: 606

Wales 2008 Defender 110 Puma 2.4 USW Zermatt Silver
Ianh wrote:
Workshop manual https://onedrive.live.com/?authkey=%21ALkd...9C85C7C171

Curtesy of member dgardel Thumbs Up

Plus read this topic for a guide, note blackwolfs comment on using 1/2 inch / 13mm deep socket. https://www.defender2.net/forum/topic29850...p;start=15


Thank you for this..! Page 3 is particularly helpful! 2008 2.4 110 Utility XS.
Post #964583 10th Sep 2022 4:29pm
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Ianh



Member Since: 17 Sep 2018
Location: Essex
Posts: 1695

United Kingdom 
BrickBox wrote:
Excuse my stupidity, but I’ve been through the files and cannot find any guide for the starter motor Confused

All I can find is an index in foreign language..


https://onedrive.live.com/?authkey=%21ALkd...mp;o=OneUp
Post #964584 10th Sep 2022 5:00pm
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custom90



Member Since: 21 Jan 2010
Location: South West, England.
Posts: 19452

United Kingdom 
It will be in the manual, but my biggest gripe with the WSM is having to spend an age looking for one item in question. Diesels Lives Matter. ⛽️🛢️👨‍🔧🧰⚙️
And if You Love the Country, then we’re on the same side ~
I got’ love for Britain, I got’ British pride’. 🇬🇧
Post #964597 10th Sep 2022 8:48pm
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BrickBox



Member Since: 05 Oct 2021
Location: Wales
Posts: 606

Wales 2008 Defender 110 Puma 2.4 USW Zermatt Silver
Just a midway update - new starter motor is on!

I went from above - coolant hoses etc removed. Definitely worth taking the bonnet off too for extra light and arm movement.

I will do an update later once it’s all hopefully back together and hopefully actually works… 2008 2.4 110 Utility XS.
Post #964743 12th Sep 2022 12:21pm
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BrickBox



Member Since: 05 Oct 2021
Location: Wales
Posts: 606

Wales 2008 Defender 110 Puma 2.4 USW Zermatt Silver
All up and running! Mr. Green

Full update inc pictures later. 2008 2.4 110 Utility XS.
Post #964753 12th Sep 2022 1:45pm
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BrickBox



Member Since: 05 Oct 2021
Location: Wales
Posts: 606

Wales 2008 Defender 110 Puma 2.4 USW Zermatt Silver
(*Novice help , not a professional - listen to advice at own risk…*)


Soooo…. Where to begin…?

After most of the advice (including Haynes manual) pointed towards getting underneath the vehicle to get the starter motor out, I did the opposite… Whistle I went from above. I just couldn’t get my head around why/how it could come out from underneath. You are working blind from underneath. The only reason to go underneath is for the 13mm underside starter bolt and the alignment of the starter when refitting.

So, from above - difficulty 3/5 - the main difficulty is keeping patient and your hand squeezed into the small areas. Didn’t need to jack the car up or remove a wheel or anything of the sort.

Tools - 13mm deep socket with union joint extension, coolant hose clip pliers, flat head screwdriver, coolant, and a couple of 8-10-13mm spanner’s for the starter nuts and a head torch.

DISCONNECT BATTERY** before starting the job.

Stage 1 - remove bonnet for as much light and access as possible.

Click image to enlarge




Click image to enlarge

Stage 2 - required mainly an extendable coolant hose clamp pliers. Literally using these makes working from the top so much easier. You will loose coolant doing it this way, I’d estimate around 3-4 litres.
The most awkward areas were removing the boost pipes jubilee clips if they’re original. I assume they were fitted at the factory while the body was off, as the flat head screwdriver heads are almost facing away from you. 13mm long reach socket and the angled universal joint attachment for the starter motor above nut. The fuel line retaining plastic clip needs to be removed so the lines become flexible to move out of the way. I had to go underneath the vehicle to undo the other 13mm nut underneath the starter motor motor (2 bolts secure it to the bell housing).

Click image to enlarge

Clear view now

Undo the electrics (making note of which way they came off) and a little wiggle to get it out..and presto..


Click image to enlarge


The starter has an alignment pin which is seen from underneath- it just slots on and then you’ll see the starter slot into place. Then you can repeat the process in reverse by starting with securing the starter motor with the 13mm bolt while your already underneath from aligning the starter.

I hope this helps in someway.

I genuinely was dreading this job from the lack of information online, or at least lack of pictures/guide that I could follow. But after some patience and possibly going the long way around, It wasn’t too bad. It took around 4-4.5 hours this time. I think I could half that time pretty easy now I know where to start. 2008 2.4 110 Utility XS.
Post #964799 12th Sep 2022 7:07pm
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