Rewire.

border · Aug 13, 2019

Well this is the bit I've been Dreading. Rebuild of 1987 110 which was Originally 2.5 na I think. But now 300Tdi from Discovery on to LT77 Box.
Anyway got to stage to Rewire, I did not take this thing apart, was bought as Rolling Chassis so did not see where wires were.
The Loom through Chassis plugs in to Bulkhead with all wires matching up as in first pic. I think the other plug to the Right is the for the Main Engine Loom from looking at other posts ect, please correct me if I'm wrong.
Rest of pics are wires from 300 engine,
Ive looked at loads of the Diagrams out there but for the life of me just cant understand them

I know there is a Load more Inside doe the Dash ect but gonna start on Engine first.
Any info Greatly Appreciated .
Thanks

dag019 · Aug 15, 2019

You will likely have the same issue I have with mine (200tdi, on a 89'chassis, 300tdi bulkhead). On mine the engine loom and bulkhead loom are the multi pin plugs you have in your second picture, but the rear wiring loom is the bullet style plugs pictures in your first. This means that unfortunately it is not as simple as just plugging everything in. For me the bulkhead and engine plugs match up, but the rear wiring loom one does not. I was lucky enough to have the rear wiring loom multi pin plug come with my bulkhead so I cut the old bullet plug off the rear loom and carefully soldered the multi pin plug on matching up all of the colours. You will either need to do similar for those that do not match, or make up a short piece of adapter loom with a bullet plug one end and a multi pin the other to ensure they connect up.
Picture three looks like alternator wiring although I would need to know the colours of the two small wire to be able to help you as to where on the alternator they attach.

Hicap phill · Aug 15, 2019

@border Have you the old engine?

border · Aug 15, 2019

dag019 said:
You will likely have the same issue I have with mine (200tdi, on a 89'chassis, 300tdi bulkhead). On mine the engine loom and bulkhead loom are the multi pin plugs you have in your second picture, but the rear wiring loom is the bullet style plugs pictures in your first. This means that unfortunately it is not as simple as just plugging everything in. For me the bulkhead and engine plugs match up, but the rear wiring loom one does not. I was lucky enough to have the rear wiring loom multi pin plug come with my bulkhead so I cut the old bullet plug off the rear loom and carefully soldered the multi pin plug on matching up all of the colours. You will either need to do similar for those that do not match, or make up a short piece of adapter loom with a bullet plug one end and a multi pin the other to ensure they connect up.
Picture three looks like alternator wiring although I would need to know the colours of the two small wire to be able to help you as to where on the alternator they attach.

Thanks Mate I will get coulors of wires to alternator. The multipin plug coulors don't match up to the coulors on bullet plug so will need to find out what goes to what. Don't suppose you have any pics of yours? Thanks Again.

Hicap phill said:
@border Have you the old engine?

No Mate don't have it

dag019 · Aug 15, 2019

border said:
Thanks Mate I will get coulors of wires to alternator. The multipin plug coulors don't match up to the coulors on bullet plug so will need to find out what goes to what. Don't suppose you have any pics of yours? Thanks Again.

the bullet connector that you have pictures is the one for the rear loom which will match up with the bulkhead as they are both the same year. It will be the engine multi pins that you will need to work out which bullet connectors they match up to. It may be more than one. I will try and get you some pictures of mine when I am home but I don't know how much help it will be as both the bulkhead and the engine are the later styled plug rather than bullets.

border · Aug 15, 2019

dag019 said:
the bullet connector that you have pictures is the one for the rear loom which will match up with the bulkhead as they are both the same year. It will be the engine multi pins that you will need to work out which bullet connectors they match up to. It may be more than one. I will try and get you some pictures of mine when I am home but I don't know how much help it will be as both the bulkhead and the engine are the later styled plug rather than bullets.

Would be easy if coulors on both ends were the same like rear loom but they are different coulors on plastics to ones on rubber ones for engine.

dag019 · Aug 15, 2019

border said:
Would be easy if coulors on both ends were the same like rear loom but they are different colours on plastics to ones on rubber ones for engine.

That will make things interesting then! Although the engine is pretty basic with very few electrical connections. Temp, pressure, glow plugs, and starter are surely about all it has? Do you have wiring diagrams for both the 300tdi engine and the original vehicle? It may just be a case of meticulously (and boringly) going through the two diagrams and matching the different colours.

Hicap phill · Aug 15, 2019

That’s why I asked if he still had the old engine.

Could you not source a 200 loom & fit to the 300 engine?
All the fittings/connectors are the same.
Get loom from a disco if you require a rev counter

border · Aug 15, 2019

dag019 said:
That will make things interesting then! Although the engine is pretty basic with very few electrical connections. Temp, pressure, glow plugs, and starter are surely about all it has? Do you have wiring diagrams for both the 300tdi engine and the original vehicle? It may just be a case of meticulously (and boringly) going through the two diagrams and matching the different colours.

So if I had both Diagrams would it be a case of joining colour to colour ? or is that just wishful thinking ??

Hicap phill said:
That’s why I asked if he still had the old engine.
Could you not source a 200 loom & fit to the 300 engine?
All the fittings/connectors are the same.
Get loom from a disco if you require a rev counter

Would the colours from 200 loom be same as mine?

Hicap phill · Aug 15, 2019

Not sure about the colours but As with @dag019
There is not much to the engine looms.
Water temp
Oil pressure
Rev counter(optional)
Alternator exciter wire
Alternator mains
Starter wire
Fuel pump live

You can wire in the glow plugs up 4cables
Think this is pic4
(Mains cable back to the battery from starter.)
Just been out to the shed,I only have part internal looms from RRC so no ends to chop for you.

border · Aug 15, 2019

Hicap phill said:
Not sure about the colours but As with @dag019
There is not much to the engine looms.
Water temp
Oil pressure
Rev counter(optional)
Alternator exciter wire
Alternator mains
Starter wire
Fuel pump live

You can wire in the glow plugs up 4cables
Think this is pic4
(Mains cable back to the battery from starter.)
Just been out to the shed,I only have part internal looms from RRC so no ends to chop for you.

Thanks Mate Does not sound to hard once I know what to join what to what

There is a Yellow and Black going to each glow plug then on to pic 4 as you said.

Hicap phill · Aug 15, 2019

Glow plugs linked together(blk & yellow) You then connect 1 end to a live (relay) off I think pic 4. Look for a small ring crimp in that loom.

Pic 1 shows your main engine loom connection
Try
White /brown oil pressure
Brown/white fuel pump
Green temp
Red/white starter solenoid
2 large brown to alternator

border · Aug 22, 2019

Been hunting about in my pile of parts that came when I bought whole thing, and Look what I found. I had a feeling the PO would have kept this,
Looks like the Original engine loom as plug matches up to mine and all colours match when plugged in. Now to find out what ends go where.
I know where number 1 goes.

ivancrx · Aug 23, 2019

No 2 is starter, No 3 looks like alternator.

Hicap phill · Aug 23, 2019

1 main loom connector(bulkhead)
2 live to starter. Red/white solenoid
3 alternator
4 either injector pump live or oil pressure.
5 think water temp

border · Aug 23, 2019

Hicap phill said:
1 main loom connector(bulkhead)
2 live to starter. Red/white solenoid
3 alternator
4 either injector pump live or oil pressure.
5 think water temp

Spot on Mate Thanks. If they do not reach do I just add more wire on ?
Also can I do away with the 300 one , or do I need anything from it ??

Hicap phill · Aug 23, 2019

Think only the live to the injection pump is missing.
Should all reach.
You will have to remove the black plug off the alternator cable & replace with ring lugs for the lives &

border · Aug 23, 2019

Hicap phill said:
Think only the live to the injection pump is missing.
Should all reach.
You will have to remove the black plug off the alternator cable & replace with ring lugs for the lives &

Thanks Mate

border · Sep 2, 2019

Back to this now, I know I should be doing one job at a time but keep jumping from job to job. So I know where wires go now thanks to Hicap Phill. Now on number 2 to Starter there is altogether 4 browns with 2 of each going to one ring connector. Do both these go on same connection as the Live coming from Battery. Number 3 has 2 brown as well do these go to same terminal on Alternator. Hope this makes sense as I'm hopeless with electrics

. Thanks everyone for help

Hicap phill · Sep 2, 2019

So all of N2(both ring conectiers)goes on the starter with a main live feed from the battery
Yes both can be connected from N3. The small cable is the exciter cable.

What does the rear of the alternator look like?
Photo may help with my brain remembering where they go

Also while you can get to the starter bolts out an earth there

Rewire.

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