200tdi won't start after bulkhead swap.

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IamRobbie

IamRobbie

Well-Known Member
Posts
2,800
Location
Derbyshire, j28 M1
As the title says.. She just won't start at all...


Now I labeled everything up when I took my old bulkhead off and ive used the old 1989 td wiring with the new TD5 dash clocks.... I have all my dash lights present that i should have and when I go to turn the key on my ignition (I kept the old ignition barrel on the new bulkhead... It just clicks at the relay near the fuses...

I've cleaned the earth from battery to gearbox and the earth from engine to chassis but still nothing... I tried to start it with a screwdriver on the starter solenoid but it struggled to turn it as if the battery was flat... I've tried jump starting it for power and still nothing. What am I missing?
 
I've also swapped the headgasket at the same time as the bulkhead but I can't see how that would make the starter not even attempt to come on.

I've double checked the ignition wiring that is correct and present..


I've tried to check for voltage at the starter plunger cable when holding the ignition but it's near on impossible with a voltage sensing voltage gauge and one pair of hands.
 
Well I've checked the back of the ignition and one brown is live the other comes live when clicked once. Then I think one of the small ones came live on the 3rd click.
 
I had the same thing, seemed like I had a flat battery when I tried to start. Did you check the earth from starter to engine(or maybe chassis)?

When this happened to me I ran a thick jump cable direct from the starter earth to the battery negative. If it starts with that then you know you have a bad earth somewhere.
 
Check for continuity on the earth at your starter relay

Then check for continuity on the wire to the starter solenoid from the starter relay l

Ime the old td ninety wiring was a bit wierd for me compared to the books and i had a purple black wire up at the top of the bulkhead ( that started black at the starter relay)in the block as my earth from the starter , it was easy to miss , no book told me i found it through probing with the multimetre.

I would charge your battery offline as well jumpstarts are hit or miss with a landy ime , my pug took forever to charge it from dead and yours sounds dead if it doesnt even turn it. start with known variables.

I fitted a 200tdi loom in the end , was a far easier solution than trying to work out the 19j wiring that had been butchered over the last 30 years
 
I have a purple/black and a black wire in my engine bay that I'm pretty sure i didnt disconect from anything...

it seems like it runs towards the drivers wing but doesnt go as far as the rest of the wing wiring..


Ive got the battery on charge and i will check the starter earth this week...

Im not sure on how to check for continuity or what it does so ill have to have a read up about it this week online.

Rest of my wiring seems fine, I fixed a friends truck which wouldnt start the other day after a small fire and that was simply an earth behind the dash clocks, thats what makes me think it could be the same earth for me, however when i removed my old bulkhead i tagged everything up and I'm 99% sure i didnt miss a single thing.
 
Ok, borrower next doors voltmeter and his hand. He turned the key whilst I held the positive on the white/red dash wire off the starter spade.... I held the negative on the engine earth point that I have previously cleaned!!!


He held the ignition on as if he was starting it..


0 volts.. Tried tracing it back but I'm unsure where it runs to as the white/red on the back of the ignition has a red line not a red dot... Looks like a date with Google to find out where and why tonight..


Oh also I borrowed a mates yellow top battery and shorted the starter and she fired up sounding very sweet after the headgasket change.. Can't wait to drive her again!!!
 
It may also be worth noting that when I put the 200tdi engine in last year I didn't put a glow plug relay (timer???) in or anything. The glow plugs came on if I held the key between position 2 and 3... I don't get any glow plug light at all at the minute... Maybe this is going to the same problem?
 
Last edited:
Yeh true. Gonna find a 200tdi wiring diagram and hope that it's not too far different from the 19jwiring I have... I suppose I could take a perm live and go through a switch to the spade connector lol..
 
Youll want the 19j wiring diagram

Dont confuse your self.

The engine needs the same connections as the 19j only the 200 does things different so it makes no sense. I was trying to combine the two for a hile and then gae up and bought a 200tdi loom .
 
relays.jpg



Ok so here goes...

Got 12v when holding ignition oat the white/red wire on the back of the ignition...

I am guessing that the relay that is to the left of the RED plastic is the starter relay, I know this because i shorted the brown and the white/red (u can only see white) together, and the truck tried to start..

I held the ignition on and didnt have any volts at small white red on the left but i did have a live 12v feed at the brown...

now the middle relay, the one with the white/red and the rest blacks, has 12v at the white/red when the key is turned and held....



So I'm out of ideas.... I can't have plugged the wrong cable onto the back of the ignition because i labelled it up.

I haven't touched the wiring at the relays, ive only unplugged and plugged things into the middle of the dash which were all labelled up and the engine bay with the bulkhead change.....


someone who's good at this stuff helppppppp please
 
Last edited:
top drive said:
Youll want the 19j wiring diagram

Dont confuse your self.

The engine needs the same connections as the 19j only the 200 does things different so it makes no sense. I was trying to combine the two for a hile and then gae up and bought a 200tdi loom .
Click to expand...

It worked before the bulkhead swap, i labelled up every single connector i unplugged, i wrote exactly the same on both halves of the connectors so nothing got confused or plugged in the wrong place.
 
And so it should have , all im saying is use the 19j diagram as looking at a 200tdi diagram when you have a 19j loom infront of you wont help.

Have you tried swapping the relays about ? Have you checked the continuity of the red white starter spade wire to the red white on the left of the starter relay ?
 
I need to check how to test for continuity and what it shows, Im guessing it tells you if its the same cable?

Yes ive swapped the relays around. Im gonna figure out continuity and thats probably gonna show me whats wrong somewhere i hope.
 
IamRobbie said:
I need to check how to test for continuity and what it shows, Im guessing it tells you if its the same cable?

Yes ive swapped the relays around. Im gonna figure out continuity and thats probably gonna show me whats wrong somewhere i hope.
Click to expand...

It confirms they're connected. Have you got a multimeter? Its the mode that usually beeps if you touch the two test probes together.

If you don't have one, go and get one ;)
 
I tested last night when the penny dropped and I tested this afternoon. I have continuity from the cable on the back of the ignition to both the white with reds.... It's noe proper confused me
 
Now please test the black earth under the starter relay to a known earth point. If thats earthed even if its not the same earth point it will show continuity.

Based on my own experiances im still odds on for the start relay not being earthed.
 
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